Safe operation of cold storage facilities - A ... - WorkSafe Victoria
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Contents1 Introduction 12 Legal obligations 23 Consultation 34 Training and supervision 45 Using these guidelines 66 Building design and structure 87 Workplace layout and <strong>facilities</strong> 118 Traffic management 169 Environmental conditions 1910 Manual handling 2411 Plant (machinery and equipment) 2912 Emergency management 3513 Acknowledgements 3814 Appendices 39Appendix 1 – Process chart for the design<strong>of</strong> a safe <strong>cold</strong> <strong>storage</strong> workplace 39Appendix 2 – Wind chill program (chart) 40Appendix 3 – Operation <strong>of</strong> LPG forklifttrucks in poorly ventilated places 41Appendix 4 – Long-term fruit <strong>storage</strong> incontrolled atmosphere rooms 44Appendix 5 – Protective Clothingfor Cold Storage – A user’s guide 46Appendix 6 – Checklist– Anhydrous ammonia refrigerating systems 58Work<strong>Safe</strong> <strong>Victoria</strong> is a trading name<strong>of</strong> the <strong>Victoria</strong>n WorkCover Authority.This publication is protected bycopyright. Work<strong>Safe</strong> encourages thefree transfer, copying and printing<strong>of</strong> this publication if such activitiessupport the purpose and intent forwhich this publication was developed.
2.Legal obligationsThe Occupational Health and <strong>Safe</strong>ty (OHS) Act 2004 (S. 21) requires employers,so far as is reasonably practicable, to provide and maintain a workingenvironment that is safe and without risk to employees’ health. Part <strong>of</strong> this isproviding employees with information, instruction, training and supervision to ensurethey are able to perform their work in a safe manner and without risk to health.This duty extends to contractors and employees <strong>of</strong> the contractor. Employers andoperators <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> should be aware they have a responsibility(S. 23) to others apart from employees.Managers <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> – as well as employees – have prescribedindividual responsibilities (S. 25) as <strong>of</strong>ficers <strong>of</strong> a company (S. 144) for ensuringthe health and safety <strong>of</strong> employees and others in the workplace.The OHS Act also requires the designers <strong>of</strong> buildings and structures to design thebuilding or structure to be safe and without risks to the health <strong>of</strong> those using itas a workplace (S. 28).While the OHS Act prescribes the general principles and duty <strong>of</strong> care provisions <strong>of</strong><strong>Victoria</strong>n health and safety legislation, there are a number <strong>of</strong> specific hazard-basedregulations (Occupational Health and <strong>Safe</strong>ty Regulations 2007) that requireemployers to identify and control risks, and consult with employees who are likelyto be affected by any activity that relates to their health and safety.More information: Occupational Health and <strong>Safe</strong>ty Act 2004Occupational Health and <strong>Safe</strong>ty Regulations 20072 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
3.ConsultationThere are specific duties within the OHS Act (Part 4) and various sections <strong>of</strong> hazardbasedregulations that require employers to consult with employees who are, or arelikely to be, affected by a range <strong>of</strong> health and safety matters. This includes identifyingor assessing hazards or risks, making decisions on how to control risks or whenchanges are proposed that may affect employee health and safety.Consultation must include independent contractors and employees <strong>of</strong> the independentcontractor/s, including labour hire employees – provided that the action or decisioninvolved is one the principal employer has, or should have, control over.In situations where health and safety representatives (HSRs) are elected byemployees to represent them, this consultation must involve the HSR (with or withoutthe involvement <strong>of</strong> the employees directly). Effective consultation between employers,employees and HSRs working within <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> is necessary to ensureworkplace hazards are identified and where possible eliminated or controlled.There are many benefits that can be gained through meaningful consultationbetween employers and employees including:• better outcomes resulting from employee input and a more comprehensiveidentification <strong>of</strong> potential workplace hazards and risk control options• ownership by employees in relation to any <strong>of</strong> the decisions that are made toeliminate or reduce risk• a more effective and efficient design and <strong>operation</strong> <strong>of</strong> plant and work processes• a better and more effective workplace layout that produces considerableefficiency gains• a healthy and safe workplace culture with a strong emphasis on co<strong>operation</strong>, and• improved productivity and a reduction in absenteeism.It is important to recognise that effective consultation during the initial design andongoing <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> will assist employers and operators. Itensures plant and equipment, as well as the structure and layout, are efficient andsuitable for the safe <strong>operation</strong> <strong>of</strong> the facility.More information: Occupational Health and <strong>Safe</strong>ty Act 2004Occupational Health and <strong>Safe</strong>ty Regulations 2007Work<strong>Safe</strong> guidance and publicationsWork<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 3
1213SubmissionsKey ProjectsThe IFPA has earned a reputation as an expertvoice in the area <strong>of</strong> reproductive and sexualhealth thanks to its excellent track record inproviding high quality medical, contraceptionand crisis pregnancy services. In 2008, theIFPA was called upon to make a submissionto the National Office for the Prevention <strong>of</strong>Domestic, Sexual and Gender - based Violenceon the development <strong>of</strong> its national strategy. IFPArecommended the inclusion <strong>of</strong> FGM in the strategy.The integration <strong>of</strong> domestic violence and familyplanning services and research into domestic andgender-based violence was also recommended.In a submission to the Joint Committee onthe Constitutional Amendment on ChildrenIFPA highlighted the noticeable gap inconstitutional protection for the independentrights <strong>of</strong> the child and stated that it does notsupport the criminalisation <strong>of</strong> consensualsexual activity between minors.In June the IFPA made a submission to theHuman Rights Commission in relation to theThird Periodic Report <strong>of</strong> Ireland under theInternational Covenant on Civil and PoliticalRights (ICCPR). The commission was told thatthe Irish Government’s continued disregard forinternational human rights norms in its abortionpolicies has resulted in Irish women continuingto have a higher percentage <strong>of</strong> later abortions,receiving less pre-abortion and follow-upmedical care, and suffering from the stigmacreated by the criminalisation <strong>of</strong> abortion. IFPAcalled for greater access to abortion services forall women within the State, particularly whena woman’s health and well being is at risk.Other Key Submissions:» In April IFPA presented a report tothe Oireachtas Health Committeeon the need for a national screeningprogramme for cervical cancer.» Submission to Irish Aid through Dochason humanitarian policy highlighting need forimproved gender analysis, the importance<strong>of</strong> reproductive health supplies and sexualand reproductive needs <strong>of</strong> adolescents.» IFPA was consulted by the EqualityAuthority for a background paper onstereotyping. IFPA contributions on images<strong>of</strong> women seeking abortion and the impact<strong>of</strong> gender stereotyping on sexual healthwere given priority in the publication.FGMOn November 25 2008, to coincide withInternational Day for the Elimination <strong>of</strong> Violenceagainst Women, Ireland was one <strong>of</strong> 15 Europeancountries to launch action plans to addressfemale genital mutilation (FGM) in their respectivecountries. This event was the culmination <strong>of</strong> years<strong>of</strong> hard work at the IFPA.IFPA was asked to develop a national plan toaddress FGM in Ireland by the EuroNet FGMAssociation as part <strong>of</strong> a 15-country project.To achieve this the IFPA brought together 17diverse organisations to form a steering committeeand produced this landmark plan <strong>of</strong> action.The document stressed the need for an interagencyapproach to address FGM in Ireland andset out three fundamental goals - prevention <strong>of</strong>the practice <strong>of</strong> FGM in Ireland, provision <strong>of</strong> qualityhealth care and support for women and girls whohave undergone FGM and contribution to theworldwide campaign to end FGM.The action plan called for:» The establishment <strong>of</strong> an inter-departmentalworking group to monitor and evaluate theprogress <strong>of</strong> the Plan <strong>of</strong> Action.» The enactment <strong>of</strong> legislation to specificallyprohibit FGM in Ireland.» Recognition that the harmful consequences <strong>of</strong>FGM are being experienced here in Ireland.Salome Mbugua, AkiDwA, & Ifrah Ahmed, Somali Community inIreland, at the launch <strong>of</strong> the action plan74 people attended the launch, which was held inthe Irish Aid Centre on Dublin’s O’Connell Street inNovember.Drugs Conference and reportIFPA organised a two-day conference entitled“Drug Use: A Reproductive and Sexual HealthPerspective” in Dundalk in April. The firstconference <strong>of</strong> its kind in Ireland, the event soughtto provide information to medical, nursing andall other pr<strong>of</strong>essionals working directly andindirectly with the drug using community aboutthe management <strong>of</strong> reproductive and sexualhealth issues. The conference formed part <strong>of</strong>a larger project comprising two training coursesfocusing on the reproductive and sexual health <strong>of</strong>the drug using community for counsellors, youthworkers and other pr<strong>of</strong>essionals working in thedrugs sector.IFPA ANNUAL REPORT 2008WWW.IFPA.IE
5.Using theseguidelinesHow to use these guidelinesThese guidelines have been divided into specific hazard or industry-based issues.While the following list may not cover all existing hazards or issues within <strong>cold</strong> <strong>storage</strong><strong>facilities</strong>, the general principles may be applied to those areas not listed in this document.The green, amber and red traffic light format will help you identify high-risk practicesand assess your workplace in order to implement safer work practices. The rationaleis simple: to reduce injury rates and compensation claims, high-risk situations mustbe addressed.Companies undertaking work practices in the RED high-risk area should be awarethat these activities may breach legislation and place the health and safety <strong>of</strong> theirworkers at risk.Where high-risk practices are used and identified in your workplace, you shouldimmediately consider practices in the GREEN low-risk column.If not practicable, you should put in place the comparable practices in the AMBERmedium-risk column. Generally, these only provide an interim solution as, in mostinstances, the GREEN solutions reflect good practice.If, however, you are able to demonstrate an appropriate risk assessment processhas been undertaken and you are able to verify the ‘reasonably practicable’ testhas been applied to the implemented controls, measures in the amber range maybe practicable.High Risk (Medium-risk) (Low-risk)The practices in thered column shouldnot be used in theworkplaces; an employerwho allows thesepractices to be used islikely to be in breach <strong>of</strong>OHS legislation.The practices in theamber column are lesseffective in reducing riskcompared to those in thegreen column and shouldgenerally be treated asinterim solutions.The practices in thegreen column are mosteffective at reducing riskand should be regardedas the target for allworkplaces.6 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
5.Using these guidelinesUnacceptablerisk columnSolutionsshouldcontinueto bereviewedas higherordercontrolsbecomemorepracticableAre any solutions fromthe green columnreasonably practicablefor the workplace?(Undertake practicability test)NOImplement solutions,reduced risk columnYESImplementa solution,preferredsolutioncolumnThese guidelines apply no matter what time <strong>of</strong> day or day <strong>of</strong> week.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 7
6.Building designand structureThere are a number <strong>of</strong> structural design factors that should be considered when planning, designing or modifying any <strong>cold</strong><strong>storage</strong> facility. When planning the design specifications for a new <strong>cold</strong> <strong>storage</strong> facility or modifications to an existing facility,the owners and operators are presented with an opportunity to capitalise on past experience and ensure the design, layoutand selection/installation <strong>of</strong> plant and equipment utilises new technology to eliminate or reduce risk while at the same timeimprove productivity.The following building design factors should be considered during the design <strong>of</strong> any new <strong>cold</strong> <strong>storage</strong> facility or modificationsto any existing facility.More information: Design <strong>of</strong> a safe <strong>cold</strong> <strong>storage</strong> workplace chart (Appendix 1)Suspended ceilingsHigh risk examples Medium risk solutions Low risk solutionsInsulated ceiling spaces or cavitiesused by employees or contractors for<strong>storage</strong> or maintenance that have:• not been designed andconstructed with safe means<strong>of</strong> access and egress• no visible or prescribed maximumload capacity to ensure it willsupport the weight <strong>of</strong> personsand or material• no perimeter or other appropriatefall protection.Suspended ceilings and ceilingcavities that have:• appropriate means <strong>of</strong> accessto and egress from the ceiling cavity• sufficient space and lightingfor maintenance or the conduct <strong>of</strong>other activities in the space• appropriately designated walkwaysand/or work platforms• suitable weight rating and arecapable <strong>of</strong> supporting workersand materials• capability <strong>of</strong> bearing additional loadfrom a build up <strong>of</strong> ice and water ifthe ceiling becomes wet• strategically positioned drainagepoints capable <strong>of</strong> removing any buildup <strong>of</strong> water.8 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
6.Building design and structureSuspended ceilings (continued)High risk examples Medium risk solutions Low risk solutionsWell designed suspended ceilingproviding a cavity space safe to accessand work in.• provisions for a hoist or othermechanical aid used for raising andlowering tools and equipment.Structural supportsHigh risk examples Medium risk solutions Low risk solutionsStructural supports or columnsthroughout buildings that:• are positioned in or adjacent tovehicle or forklift traffic areas• are not clearly visible andeasily defined• impede or restrict the movement<strong>of</strong> forklift and pedestrian traffic• increase thermal conduction.Structual supports or columns withintraffic areas that are:• painted to increase visibility• appropriately covered to reduceimpact and increase visibility.Building and structure designed ormodified to ensure:• no internal structural columnshinder or obstruct forklift or orderpicking activities• any internal structural supportsor columns positioned within thebuilding structure or racking• are insulated and heated to limitthermal conduction.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 9
6.Building design and structureAir flowsHigh risk examples Medium risk solutions Low risk solutionsPoor workplace design and layoutwith refrigeration plant and equipmentthat has:• unnecessarily high air velocity thatcreates high wind chill• fans directed onto employee workor traffic areas• noise levels at or above the 85dB(A)exposure standard.Design layout and selection <strong>of</strong> plantto ensure:• evaporators are positioned to reduceairflows and limit wind chill andsnow formation• there are safe and easy means <strong>of</strong>access to plant for maintenance staff• air curtains or rapid roller doorsprovide warm work areas foremployees while maintaining <strong>cold</strong>environment for product• interlocked refrigeration fans thatstop when people are in area.Flooring systemsHigh risk examples Medium risk solutions Low risk solutionsPoor concrete flooring system designand construction resulting in:• tripping hazards created by uneven,cracked or broken concrete• excessive number, size, and position<strong>of</strong> expansion joints• unsafe internal forklift traffic areasand roadways created by unevenfloor surface (due to number, sizeand position <strong>of</strong> expansion joints orfrost heave).Flat concrete flooring system that has:• racking system strategicallypositioned over expansion joints• metal plates fixed overexpansion joints.A well designed, constructed andmaintained concrete slab floor that:• is solidly constructed, level andfree <strong>of</strong> cracks or damage• is post-tensioned to remove needfor expansion joints• minimises the number and impact<strong>of</strong> expansion joints at design stage• has sufficient insulation witha suitable vapour barrier or sub-floorheating to prevent frost heave• is sealed to prevent or minimiseconcrete dust• has joints protected with steel angles.10 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
7.Workplace layoutand <strong>facilities</strong>While the design, layout and specification <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> provides the best opportunity to design and/or engineer outthe risks to employees associated with workplace hazards, redesigning or modifying existing <strong>facilities</strong> can also be a cost-effectiveway to reduce risk. The re-design <strong>of</strong> the workplace layout and the relocation <strong>of</strong> existing amenities and <strong>facilities</strong> allow <strong>cold</strong> <strong>storage</strong>facility owners and operators to better utilise the existing structure while reducing risk and improving product flow.Redesigning or modifying an existing facility also enables employers to add or reposition racking systems, ensure employeeamenities are strategically positioned close to work areas, and that access to these amenities does not require employees ortruck drivers to travel through forklift or vehicle traffic areas. These modifications also provide employers with an opportunityto explore the level <strong>of</strong> risk reduction and efficiency benefits associated with the introduction <strong>of</strong> the most recent and up-to-datetechnology in racking systems and traffic management.More information: AS/NZS 1680.1.2006Interior and workplace lighting – General principles and recommendationsVisibilityHigh risk examples Medium risk solutions Low risk solutionsFacility has an inadequate level <strong>of</strong>visibility due to:• poorly designed and positionedgeneral or task lighting in trafficor work areas• product <strong>storage</strong> that is in or acrossdesignated walkways or roadways• blind spots created by the temporaryor permanent <strong>storage</strong> <strong>of</strong> productpallets adjacent to roadways ortraffic areas• pedestrian, forklift and vehicletraffic intersections that createblind corners (e.g. ends <strong>of</strong> racking,doorways into and from trucks atloading dock).Facility has risk controls measures toimprove visibility that include:• adequate general lighting with noconsideration given to task lightingneeds or shadows created byracking, etc.• use <strong>of</strong> mirrors at blind corners• use <strong>of</strong> bollards and/or gates atpedestrian and forklift intersections,or blind corners• procedures requiring pedestrian,forklift and vehicle traffic to stopand look both ways at intersections• procedures requiring vehicles tosound horns when approachingintersections and when enteringor exiting buildings.Good visibility as a result <strong>of</strong> the designand the layout <strong>of</strong> the facility whichensures that:• adequate lighting has been designedand appropriately positioned in alltraffic and work areas• unobstructed and clear walkwaysand roadways where:- vehicles and pedestrian traffichave clear uninterrupted visibilityalong path <strong>of</strong> travel; and- layout and design <strong>of</strong> trafficand work areas eliminatespedestrian vehicle interaction(e.g. blind corners).Refer: AS/NZS 1680.1.2006Interior and workplace lighting – Generalprinciples and recommendationsWork<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 11
7.Workplace layout and <strong>facilities</strong>AislesHigh risk examples Medium risk solutions Low risk solutionsPoor workplace design and layout<strong>of</strong> <strong>storage</strong> and work areas due toaisles that:• are not wide enough to easily andsafely manoeuvre forklift trucks orother equipment• terminate at blind corners andintersect with roadways or forklifttraffic areas (e.g. ends <strong>of</strong> racking)• have product or material storedacross or within aisles• are used by both pedestrian andvehicular traffic at the same time• have inadequate lighting due toposition or type <strong>of</strong> lighting.Use <strong>of</strong> risk controls and proceduresfor aisles that:• allocate an aisle for order pickingor forklift use• have manually operated barriersor gates across aisles during orderpicking or use by forklifts• prescribe a three metre separationdistance between pedestrianand forklifts• prescribe that pedestrians haveright <strong>of</strong> way.Well designed layout <strong>of</strong> <strong>storage</strong> areaswith aisles that:• have sufficient and welldesigned lighting• have designated and physicallyseparate pedestrian and forklifttraffic areas (e.g. separatepicking aisles)• are wide enough to manoeuvreforklifts and pallet trucks intoposition during the placementor retrieval <strong>of</strong> product• are wide enough to allow forexpected volume <strong>of</strong> pedestrian trafficand any pedestrian carried loads• eliminate pedestrian and forkliftintersections (blind corners) at theends <strong>of</strong> racking aisles.AmenitiesHigh risk examples Medium risk solutions Low risk solutionsFacilities and amenities for employeessuch as lunch rooms, showers andtoilets that:• are not easily accessible or arelocated far away from work areas• are poorly designed, unclean and/ornot in a hygienic condition• do not have any or adequate First Aid<strong>facilities</strong> and/or trained First Aid staff• are poorly equipped and do not haveadequate <strong>facilities</strong> for:- peak number <strong>of</strong> employees(e.g. labour hire/casuals)- truck drivers or visitors• do not have appropriate warm up<strong>facilities</strong> that:- are suitably heated- are clean and well maintained- have suitable drying cabinetsfor employee personalprotective equipment (PPE).Facilities and amenities that are:• well designed, adequately equippedand clean• designed and equipped toaccommodate the maximumnumber <strong>of</strong> employees and visitors(e.g. truck drivers)• easily accessible from all work areas• located to eliminate or minimise anyinteraction between pedestrian andvehicle traffic• well equipped with clean andcomfortable warm up rooms• designed to allow for the <strong>storage</strong>and drying <strong>of</strong> employee PPE.Refer: Code <strong>of</strong> Practice for WorkplacesAppropriately designed and resourcedFirst Aid <strong>facilities</strong> with sufficientnumbers <strong>of</strong> trained staff who areaccessible to employees.Refer: Code <strong>of</strong> Practice for First Aidin Workplaces12 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
7.Workplace layout and <strong>facilities</strong>Battery <strong>storage</strong> and recharging areasHigh risk examples Medium risk solutions Low risk solutionsInappropriate and poorly designedbattery recharging and <strong>storage</strong>areas that:• are positioned on loading docks orhigh vehicular or forklift traffic areas• are within enclosed confinedareas/rooms with little or nonatural/mechanical ventilationto disburse or remove fumes• do not comply with theDangerous Goods (Storage &Handling) Regulations 2000• do not have enough spacefor manoeuvring and the safe<strong>operation</strong> <strong>of</strong> lifting equipment• do not have appropriate PPE readilyavailable for employees (e.g. faceshields, gloves, aprons, boots)• do not have appropriate andeasily accessible emergencyequipment (e.g. safety showersand eyewash <strong>facilities</strong>).Appropriately designed battery <strong>storage</strong>and recharging areas that:• are naturally or mechanicallyventilated• are designed and operated inaccordance with the DangerousGoods (Storage & Handling)Regulations 2000Refer: AS 2359.6 Powered IndustrialTrucks – Part 6 <strong>Safe</strong>ty CodeAppropriate space, ventilation and<strong>facilities</strong> to safely charge forklift batteries.• provide sufficient room for easyaccess and the safe use <strong>of</strong> liftingplant equipment to remove, storeand replace batteries• have batteries positionedon racks or secure charginglocations providing protectionfrom impact damage• have charging systemsdesigned and installed to suitthe <strong>cold</strong> <strong>storage</strong> environment(e.g. moisture, water)• have appropriate personal protectiveand emergency safety equipment(e.g. safety showers and eyewash <strong>facilities</strong>).Refer: AS 4775.2007 Emergencyeyewash and shower equipmentWork<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 13
7.Workplace layout and <strong>facilities</strong>Racking systemsHigh risk examples Medium risk solutions Low risk solutionsPoorly designed racking systems that:• do not identify safe working load(Rated Load Capacity)• are not appropriately designedor manufacturedInappropriate racking used to stockproduct which is not rated, damagedand/or in poor condition.• are overloaded or exceedmanufacture specificationsAppropriately selected, well designedracking systems that:• have been specifically selected forthe purpose for which they areintended (e.g. manual order picking)• have been designed and installedto the appropriate standardsand specifications• are regularly inspected and maintained• clearly display maximum height andrated capacity (kg) limits• have appropriate levels <strong>of</strong> collisionprotection to prevent forklift damageand potential structural failure(e.g. bollards, barriers)• have design features that allow theeasy placement and secure <strong>storage</strong><strong>of</strong> pallets and product• was designed and installed so as notto obstruct or restrict the effect <strong>of</strong>ceiling mounted sprinklers or otherfire protection systems.Refer: AS 4084 Supp 1-1993 : Steel<strong>storage</strong> racking – Commentary(Supplement to AS 4084-1993)Product stacked haphazardly in aisles dueto a lack <strong>of</strong> suitable racking space.• exceed manufacturer’s maximumspecified height for portable racking• exceed manufacturer’s maximumstack height for stillages• are damaged or not maintained tomanufacturer specifications• are not provided with adequatecollision protection to preventdamage by forklifts• obstruct ceiling mounted sprinklersor other fire protection equipment.14 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
7.Workplace layout and <strong>facilities</strong>Staging areaHigh risk examples Medium risk solutions Low risk solutionsInadequate and poorly designedstaging areas that:• have no physical separation <strong>of</strong>pedestrian and forklift traffic areas• have no designated area for the<strong>storage</strong> or holding <strong>of</strong> consignments• does not have protected or clearlydefined roadways or walkways• creates blind corners through thepositioning <strong>of</strong> pallets <strong>of</strong> product nextto pedestrian forklift intersections• are crowded with not enough spacefor the number <strong>of</strong> consignments andsafe movement <strong>of</strong> pedestrianand forklift traffic.A staging area that relies on procedures,line markings and other forms <strong>of</strong>administrative control measures toseparate pedestrian and forklift traffic.Staging areas which are well designedand have a layout that has:• all doorways between staging areas,refrigerated trucks, cool rooms andfreezers have been designed toprevent snowing or a build up <strong>of</strong> iceon walls and floor areas• enough space to cater for largeconsignments and overflow orpeak workloads• clearly marked holding areasdefined and strictly maintained• clearly defined and protectedpedestrian walkways and work areas(e.g. physical guard railing or barriers).Clearly marked staging aisles.Dock levellers and loading rampsHigh risk examples Medium risk solutions Low risk solutionsUnsuitable and poorly designed dockareas with dock levellersor loading ramps that:• are not suitable or cannot beadjusted to enable mechanicalaids to be used during loadingand unloading• are not <strong>of</strong> sufficient size or structuralcapacity for the vehicles or theequipment being used• cannot be retracted fully when not inuse and so become a tripping hazard.Well designed dock areas with docklevellers and loading ramps that:• are suitable for the purposefor which they are intendedand regularly inspected andappropriately maintained• are <strong>of</strong> sufficient size, structuralcapacity and are adjustableenabling the use <strong>of</strong> variousmechanical aids used during theloading and unloading <strong>of</strong> trucks• provide safe same level accessto the rear <strong>of</strong> trucks• fold away to form continuoussurface with dock.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 15
8.TrafficmanagementThe constant movement <strong>of</strong> road transport vehicles, the <strong>operation</strong> <strong>of</strong> forklifts and othermobile plant – and the potential for interaction with pedestrians – presents significanttraffic management issues in <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong>.Good traffic management is important for the safe and efficient movement <strong>of</strong>pedestrian and vehicles in and around <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong>. Both the designers andoperators <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> have responsibilities to ensure the facility’s design,layout and <strong>operation</strong> eliminates, or reduces so far as is practicable, the risksassociated with traffic management.Working in the <strong>cold</strong> may mean that when vehicles with windscreens and pedestrianswith glasses move from one temperature to another visibility is affected by condensationon the windscreen or glasses.The <strong>cold</strong> environment and the movement <strong>of</strong> forklifts in and out <strong>of</strong> freezers may resultin floors becoming wet and slippery. A traffic management plan must ensure issues todo with visibility and wet, slippery floors, and the risks these environmental conditionspresent, are considered and addressed.Traffic management plans must be developed, implemented and regularly reviewedin consultation with employees. The consultative process can assist the <strong>cold</strong><strong>storage</strong> facility owner and/or operator to identify, eliminate or significantly reduceany risk created by interactions between pedestrians, forklifts or other forms <strong>of</strong>vehicular traffic.Broader consultation with employer and employee representative bodies can alsoassist in identifying new or advanced technologies that may eliminate or reducerisk while at the same time providing operators with substantial efficiency andproductivity gains.The following examples <strong>of</strong> high risk activities and corresponding risk control solutionsare not exhaustive however they may assist the operators <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong>to identify and appropriately control risks associated with any interaction betweenpedestrians and vehicle traffic.More information: Australia Standard AS 4024.1Work<strong>Safe</strong> publications: Forklift <strong>Safe</strong>ty Reducing the Risk<strong>Safe</strong>ty by Design – Eliminating manual handling injuriesin road transport16 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
8.Traffic managementTraffic management:High risk examples Medium risk solutions Low risk solutionsFacility does not have a trafficmanagement plan to control risksassociated with:• poorly designed pedestrian andvehicular work areas• employees and visitors (e.g. truckdrivers) having to cross vehicletraffic areas or roadways to accessamenities or <strong>facilities</strong>• inadequate lighting and poor visibility• blind corners where pedestrian andforklift or other vehicle trafficintersect (e.g. ends <strong>of</strong> racking,loading docks, doorways openingdirectly onto roadways)• vehicle and pedestrian trafficusing the same aisles, roadwaysand doorways• forklifts or other mobile plantoperating in pedestrian work areas• walkways and work areas withno physical separation betweenpedestrians and forklift andvehicle traffic• a lack <strong>of</strong> sufficient room or area tosafely manoeuvre forklifts or roadtransport vehicles.Facility relies on risk controls that:• consist solely <strong>of</strong> safe workprocedures and signage• require all those on site to wearhigh visibility clothing• require pedestrian and vehicletraffic to slow down, stop and look• require all forklifts and vehiclesapproaching intersections orentering or exiting buildings tosound their horns• prescribe separation distancesbetween pedestrian and forklift traffic• require forklifts and vehicles to giveway to pedestrians• has floor line marking to definepedestrian work areas and walkwaysfrom forklift and other vehiculartraffic areas• use bollards/gates acrosswalkways to slow and obstructpedestrian traffic• has mirrors to increase visibilityat blind corners.Good workplace design andlayout with a traffic managementplan which ensures:• the safe and efficient movement<strong>of</strong> pedestrian and vehicular traffic• <strong>facilities</strong> and amenities arestrategically positioned toeliminate pedestrian andvehicular traffic interaction• traffic and work areas have sufficientlighting and there is good visibility(e.g. street lighting at intersections)• pedestrian work areas and walkwaysare physically separated from forkliftand other vehicular traffic (e.g.elevated work areas and walkways)Innovative racking design provides safewalkways for pedestrians.• guard railing or physical barriers arepositioned out from and across thefront <strong>of</strong> pedestrian doorways leadingto internal or external roadways• protected walkways that changedirection to increase visibility atdoorways and pedestrian forkliftintersections• pedestrian walkways are suitablefor the volume <strong>of</strong> pedestrian traffic• there is sufficient space and roomto safely manoeuvre forklifts• the different characteristics, sizeand turning circles <strong>of</strong> various types<strong>of</strong> road transport vehicles.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 17
8.Traffic managementForklift loading and unloadingHigh risk examples Medium risk solutions Low risk solutionsFacility has no adequate risk controlmeasures to protect people during theloading and unloading <strong>of</strong> trucks and:• allows unrestricted access to thedock area by pedestrians duringloading and unloading• has designated pedestrian walkwaysthat cross the path <strong>of</strong> reversingforklifts at blind corners (e.g. rear<strong>of</strong> trucks on dock area)• relies on signage as the only wayto warn pedestrian, forklift operatorsand truck drivers to be aware <strong>of</strong>other traffic• relies on safe work proceduresthat require truck drivers, forkliftoperators, and pedestrians to stopand look when approachingor at intersections• does not prevent any deliberate orinadvertent movement <strong>of</strong> the truckduring loading or unloading (e.g.driver may enter cab and move truckduring loading/unloading process).Facility relies on the use <strong>of</strong> administrativerisk controls that may include:• the use <strong>of</strong> spring loaded gatesor bollards on walkways to impedepedestrian traffic and give themtime to stop and look• strategically positioned mirrors atblind corners• flashing or static lights to warnpedestrians <strong>of</strong> forklifts activity atthe rear <strong>of</strong> trucks• designated protected areas fordrivers to stand during loadingand unloading• signage used with other riskcontrol measures• safe work procedures designed toprevent the movement <strong>of</strong> trucks fromthe loading dock during loading andunloading (e.g. use <strong>of</strong> wheel chocksand the surrendering <strong>of</strong> keys).Measure to control the risks to anypedestrian traffic during the loadingand unloading <strong>of</strong> trucks on roadwaysor dock areas should ensure that:• pedestrian access to the dock areaduring any loading and unloading<strong>of</strong> the truck by forklifts is restricted• where pedestrian walkways areacross the rear <strong>of</strong> trucks, thereare electronic sensors andinterlocked gates that preventpedestrian access during forkliftthe <strong>operation</strong> <strong>of</strong> forklifts(Reference AS 4024)• truck drivers are able to monitor andremotely supervise the loading<strong>of</strong> trucks through the use <strong>of</strong> remotevisual and audio monitors• electronically interlocked systemsthat physically restrain trailers andprevent their deliberate orinadvertent movement from theloading dock until loading orunloading has been completed anddock doors are closed and locked• appropriately designed andpositioned signage is usedin conjunction with other riskcontrol measures.18 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
9.EnvironmentalconditionsWhile there are some environmental factors specific to the <strong>cold</strong> <strong>storage</strong> industry,there are other environmental hazards and risks that are well known across arange <strong>of</strong> industries and as such have prescribed standards and well documentedguidance material.Environmental hazards in the <strong>cold</strong> <strong>storage</strong> industry include:• working in <strong>cold</strong> conditions• slips, trips and falls• noise• hazardous atmospheres• lighting.In workplaces where employee exposure to <strong>cold</strong> is identified as a workplace hazardemployers must ensure appropriate risk-control measures that protect employees andensure body heat is retained have been put in place.Employers in the <strong>cold</strong> <strong>storage</strong> industry need to recognise the impact <strong>of</strong> <strong>cold</strong> stressand the potential for hypothermia, and how thermal stress may increase fatigue andaffect the ability <strong>of</strong> individual employees to work in a manner that is safe and withoutrisk to themselves and other employees.The effects a <strong>cold</strong> work environment can have on individual employees should alsobe recognised and employers should conduct regular health monitoring to ensureexposure to <strong>cold</strong>, or rapid changes in temperature, do not have an adverse impacton the health and safety <strong>of</strong> employees.Poorly ventilated spaces such as cool stores, freezer rooms and controlledatmosphere rooms may present hazardous atmospheres. A poorly ventilated spacemay become dangerous if there is an unsafe level <strong>of</strong> atmospheric contaminantsor the oxygen level is unsafe.Some examples <strong>of</strong> dangerous work in poorly ventilated places include:• liquid petroleum gas (LPG), petrol or diesel forklift trucks in cool stores or freezerrooms – dangerous levels <strong>of</strong> carbon monoxide may build up where poorly tunedLPG, petrol or diesel forklift trucks operate and ventilation is insufficient• activation <strong>of</strong> controlled atmosphere rooms used for long-term <strong>storage</strong> <strong>of</strong> fruit– the oxygen level in controlled atmosphere rooms may be as low as 2% andexposure will be life-threatening.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 19
9.Environmental conditionsThe following environmental hazards and the corresponding risk control measures are not exhaustive, however they may assistemployers and the operators <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> to identify and control risks:More information: Operation <strong>of</strong> LPG forklift trucks in poorly ventilated places (Appendix 3)Long-term fruit <strong>storage</strong> in controlled atmosphere rooms (Appendix 4)Protective Clothing for Cold Storage – A Users’ Guide (Appendix 5)ColdHigh risk examples Medium risk solutions Low risk solutionsExposure <strong>of</strong> employees to the effects<strong>of</strong> wind chill that may contribute to<strong>cold</strong> stress or hypothermia.Refer: Wind chill chart (Appendix 2)The following factors may contributeto <strong>cold</strong> stress or hypothermia:• a level <strong>of</strong> physical activity thatresults in sweating and asubsequent decrease in employeebody temperature• inadequate supply <strong>of</strong> appropriatedry protective clothing and footwear• employees with medical or otherconditions that may be affectedby <strong>cold</strong>• employees who are moresusceptible to <strong>cold</strong> stress dueto effects <strong>of</strong> drugs or alcohol• employees who are not experiencedor acclimatised to <strong>cold</strong> workenvironments are appropriatelytrained and supervised• thermal personal protective clothingand equipment that is inadequateand or poorly maintained.Administrative risk control measuresthat prescribe:• time limits for employees workingin the <strong>cold</strong>• rest periods for employees tospend in warm up rooms.The use <strong>of</strong> appropriate personalprotective equipment that is:• provided and appropriately maintained• generically issued and suitable forthe <strong>cold</strong>• supplied to employees to work inthe <strong>cold</strong> for a limited period <strong>of</strong> time(e.g. five minutes in freezer).Risk to employees from workingin the <strong>cold</strong> and their exposure tothermal stress has been eliminatedor controlled by:• using fully automated plant andequipment able to mechanicallytransfer product to and from <strong>cold</strong><strong>storage</strong> areas• design and layout <strong>of</strong> theworkplace and:- the selection and positioning <strong>of</strong>refrigeration plant and equipment- the velocity and direction <strong>of</strong> <strong>cold</strong>air from the refrigeration plantand equipment- the use <strong>of</strong> forklifts and mobileplant fitted with insulatedand heated cabins• elimination <strong>of</strong> physical activity thatmay cause sweating and a subsequentdecrease in body temperature• pre-employment medicalexaminations and health monitoringsystems are in place to ensureemployees with medical or otherconditions are not exposed to, andor affected, by the <strong>cold</strong>• individually issued and fittedpersonal protective clothing andequipment that is suitable for the<strong>cold</strong> work environment and replacedwhen wet or damaged.Refer: Protective Clothing for Cold Storage– A Users’ Guide (Appendix 5)20 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
9.Environmental conditionsNoise (continued)High risk examples Medium risk solutions Low risk solutions• audiometric testing for employeesexposed to noise levels that exceedthe exposure standard is conducted• employees are provided withappropriate information, instructionand training on noise and the properuse <strong>of</strong> risk control measures.Hazardous atmospheresHigh risk examples Medium risk solutions Low risk solutionsHazardous work environment createdby a carbon monoxide exhaustemmission from the use <strong>of</strong> a petrol ordiesel powered forklift truck or similarpowered plant and equipment in poorlyventilated places such as freezers,chillers and <strong>cold</strong> store rooms.Hazardous work environment createdby excessive carbon monoxideemissions from the use <strong>of</strong> LPGpowered forklift trucks or similarpowered plant in poorly ventilatedplaces such as freezers, chillers and<strong>cold</strong> store rooms.There are no adequate risk-controlmeasures in place to control the riskto employees from entering controlledatmosphere store rooms which maybe contaminated and oxygen deficient.Risk control measures and safe workprocedures for employees enteringor working in poorly ventilated placesthat include:• regular testing and monitoring<strong>of</strong> exhaust emissions from LPGpowered forklifts or similar plantoperating in poorly ventilated places• regular tuning <strong>of</strong> LPG poweredforklifts to ensure exhaust emissionsdo not exceed prescribed limits• formal recording <strong>of</strong> forkliftmaintenance including the testingand monitoring <strong>of</strong> exhaust emissions• use <strong>of</strong> mechanical ventilation toclear any carbon monoxide or otherairborne contaminant from withinthe work environment.Documented safe work procedures forthose entering or working in ControlledAtmosphere (CA) store rooms include:• appointing an authorised personresponsible for formally monitoring,recording, and controlling all accessto and from these rooms• closely supervising all employeesand all work within CA store rooms• ensuring appropriate signage isdisplayed on doors and any entrypoint into a CA store room• the provision <strong>of</strong> adequate naturalor mechanical ventilation.• Replacement <strong>of</strong> petrol, dieseland LPG forklift trucks with electricforklift trucks in all poorly ventilatedplaces (e.g. freezers, chillers, and<strong>cold</strong> <strong>storage</strong> rooms).Refer: Operation <strong>of</strong> LPG forklift trucks inpoorly ventilated places (Appendix 3)The use <strong>of</strong> remote or totally automatedmechanical risk control measures thatdoes not require anyone to enter aCA store room until the atmosphere isclear <strong>of</strong> any airborne contaminant andoxygen levels are at appropriate levels.Refer: Long-term fruit <strong>storage</strong> in controlledatmosphere rooms (Appendix 4)22 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
9.Environmental conditionsHazardous atmospheres (continued)High risk examples Medium risk solutions Low risk solutions• monitoring oxygen levels before andduring any entry into CA store rooms• having appropriate controlsystems capable <strong>of</strong> securelyisolating the system for chargingthe CA store room• emergency procedures for theremoval or rescue <strong>of</strong> people fromthe CA store room• adequate training <strong>of</strong> employees whomay be required to supervise orenter a CA store room.LightingHigh risk examples Medium risk solutions Low risk solutionsGeneral and task lighting at theworkplace for employees, forkliftoperators and truck drivers isinadequate and:• general and task lighting does notmeet the required lighting standards• does not provide required degree<strong>of</strong> luminance• is not inspected and tested toensure an appropriate level <strong>of</strong>luminance is provided and maintained• poor workplace design and layoutcreates shadows• prevents or restricts easy access tolighting for maintenance purposes.Internal and external general purposeand task lighting throughout theworkplace has been designed andinstalled to ensure that:• lighting provided is <strong>of</strong> anappropriate standard and providesadequate luminance• lighting is suitable for itsintended purpose, and can beeasily reached for maintenanceor to be replaced• where a specific or high degreeluminance is required, task andgeneral lighting is regularlyinspected and tested to ensurethe appropriate level <strong>of</strong> lightingis maintained.Refer: AS 1680.1.2006 Interior andWorkplace Lighting.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 23
10.Manual handlingIn the <strong>cold</strong> <strong>storage</strong> industry, musculoskeletal disorders (MSD) caused as a result<strong>of</strong> hazardous manual handling tasks result in significant costs to the industry –in human and financial terms.Manual order picking, manual loading and unloading <strong>of</strong> road transport vehicles andcontainers result in a number <strong>of</strong> these injuries. It is recognised that <strong>cold</strong> workenvironments may increase the likelihood and the potential severity <strong>of</strong> any injury ormusculoskeletal disorder.To control the risk to employees from hazardous manual handling, employers mustconsult with employees and relevant HSRs. Consultation may involve exploringbenefits <strong>of</strong> any new technology which may be used in warehousing or other similarindustry. The selection and implementation <strong>of</strong> appropriate technology can effectivelycontrol risks associated with hazardous manual handling while at thesame time provide employers with efficiency gains and reduced costs.The key to manual order picking is to ensureemployees are able to handle items betweenshoulder and knee height at all times. This isreferred to as the Best Working Zone (BWZ),and together with ensuring that the item and isclose to their body, is the optimum position whenlifting. Items can be maintained within the BWZeither through workplace design or by usingappropriate equipment.There are a number <strong>of</strong> other factors that must beconsidered to reduce the number <strong>of</strong> injuries in <strong>cold</strong><strong>storage</strong> environments. These factors include thefrequency <strong>of</strong> handling, the weight and shape <strong>of</strong> theobject being lifted, the position <strong>of</strong> the object, thedistance or reach required to lift, push or pull anobject, whether handles are provided, any difficultyin handling the object (how slippery the object is),the use <strong>of</strong> gloves and any twisting <strong>of</strong> the body.GREEN - LOW RISKAMBER - MEDIUM RISKRED - HIGH RISK24 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
10.Manual handlingThere are other environmental factors unique to the <strong>cold</strong> <strong>storage</strong> industry that mustalso be considered to reduce the risk <strong>of</strong> MSD to employees. These environmentalfactors relate to manual handling tasks being undertaken in a <strong>cold</strong> work environmentand the accumulation <strong>of</strong> water or ice on floor surfaces that may make floors slipperyfor employees working in that environment.There are sections <strong>of</strong> the <strong>cold</strong> <strong>storage</strong> industry that have prescribed pick rates foremployees. Unreasonable work practices may increase the risk <strong>of</strong> an MSD becausethey can encourage employees to skip meal and rest breaks to meet prescribed pickrates or achieve bonus payments.Work practices that promote excessive work rates or extended shift lengths soemployees can achieve bonuses should be avoided. Senior and line managers<strong>of</strong> these <strong>facilities</strong> have prescribed responsibilities under the Occupational Healthand <strong>Safe</strong>ty Act 2004 either as <strong>of</strong>ficers <strong>of</strong> a company (S. 144) or as employees(S. 25) for ensuring the health and safety <strong>of</strong> fellow employees and others inthe work place.The Occupational Health and <strong>Safe</strong>ty Regulations 2007 (Part 3 – Manual Handling)require an employer to identify tasks undertaken or to be undertaken by an employeeinvolving hazardous manual handling. The employer must also ensure the risk <strong>of</strong> anMSD associated with a hazardous manual handling task is eliminated so far as isreasonably practicable. As a part <strong>of</strong> a review <strong>of</strong> a task following an MSD, it couldwell be expected that the contribution <strong>of</strong> the picking rate would be examined andpossibly modified.More information:Work<strong>Safe</strong> publications: Code <strong>of</strong> Practice for Manual HandlingA Guide to Manual Order PickingManual Handling in the Red Meat IndustryWork<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 25
10.Manual handlingOrder pickingHigh risk action Source <strong>of</strong> risk Medium risk solutions Low risk solutions• bending the back forwardor sideways more than20 degrees• twisting the back morethan 20 degrees• lifting and lowering itemsand exerting force whilein an awkward posture• exerting force while liftinglowering or twisting theback more than twicea minute• with long duration (> 30minutes continuouslyor > 2 hours over thewhole shift)• the application <strong>of</strong> highforce to lift, carry, push,pull or otherwise moveor restrain heavy loads.These actions may occurin situations listed under‘potential source <strong>of</strong> risk’or in combination withother work activities.Transferring product frompallets positioned on thefloor within a racking systemand on to pallets on the flooror lower shelves or trolleys.Picking or replenishing itemsfrom below knee height.Lifting products from belowthe knees.Repetitive picking orreplenishing items fromabove shoulder height withhigh force or long duration.Reducing risks may involvechanges to one or more <strong>of</strong>the following risk factors:• adjustable shelf heightsto allow employees topick from Best WorkingZone (BWZ)• height adjustable palletlifters or stands to allowemployees to stack itemsonto pallets in BWZ• pick rates that encourageemployees to take restbreaks and work safely• use <strong>of</strong> pick sticksto pull items towardsthemselves to eliminateforward reaching• plastic slip sheets orsolid top pallets toreduce resistance andthe force required whensliding items.Fully automated andcomputerised order picking<strong>facilities</strong> that do not requireany manual handling <strong>of</strong> items.Racking design, workplacelayout and work practicesensure that:• all order pickingundertaken ensuresemployees are alwaysworking within the BWZ.Carton live <strong>storage</strong> rackingwith no prescribed pick rates.Lifting products from abovehead height.Prescribed pick rates orbonus system encouraginghazardous manual handlingto be undertaken withoutprescribed rest or meal breaks.Well-designed rackingsystems with slip sheetsor solid based plastic palletson roller conveyor shelvingthat is sloped forward todecrease resistance andassist access to boxes at therear <strong>of</strong> the pallet.26 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
10.Manual handlingOrder picking (continued)High risk action Source <strong>of</strong> risk Medium risk solutions Low risk solutionsPicking is to fixed heightconveyor, adjustable heighttrolley, height adjustablepallet mover, or roll cage.Refer: Work<strong>Safe</strong> publication,Guide to Manual Order PickingLoading & unloadingHigh risk action Source <strong>of</strong> risk Medium risk solutions Low risk solutionsApplication <strong>of</strong> high forcewhen lifting, carrying, andstacking items.Repetitive application <strong>of</strong>force while in an awkwardposture, e.g. more thantwice a minute, or with longduration (> 30 minutescontinuously or > 2 hoursover the whole shift).These actions may occurin situations listed under‘potential source <strong>of</strong> risk’ orin combination with otherwork activities.Manually handling itemsinto or out <strong>of</strong> truck pansor containers, refrigeratedor not, including:• handling items to therear <strong>of</strong> the container ortruck pan• carrying items intoor out <strong>of</strong> containers ortruck pans• securing or releasingload binders• installing or removingfalse floors• opening or closing doors.Product items may includecarcasses, boxed cartons etc.Potential sources <strong>of</strong>risk include:• position <strong>of</strong> the product atpick up and at placement• work practices whereemployees do nottake prescribed mealor rest breaks• weight <strong>of</strong> the item.Reducing risk may involvechanges that may impacton the risk factors throughthe use <strong>of</strong> one or more <strong>of</strong>the following:• a conveyor or othermechanical aid totransfer product intoor out <strong>of</strong> truck pansor containers• a pallet lifter to presentproduct within the BWZduring manual loading orunloading from pallets• job rotation and or regularrest breaks for employeesinvolved in manualloading and unloading.Eliminate or substantiallyreduce any risk to employeeswhile loading and unloadingrefrigerated truck pans and/orcontainers employers should:• negotiate with suppliersand customers to ensurethat product is suppliedon slip sheets or palletsso any loading orunloading can beundertaken mechanically(e.g. forklift or walkiestacker), or• where manual loadingand or unloading isrequired use heightadjustable reach conveyoror similar mechanical aidsto ensure employees areworking within the BWZ.Extendable conveyor systemto assist manual loading/unloading <strong>of</strong> containersWork<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 27
10.Manual handlingHandling empty palletsHigh risk action Source <strong>of</strong> risk Medium risk solutions Low risk solutionsHigh force – exertinghigh force while in anawkward posture.Removal <strong>of</strong> empty palletsManual removal <strong>of</strong> emptypallets from floor levelwithin a racking system andonto a forklift or pallet jackfor removal.Manually lifting, carrying ordragging and then stacking<strong>of</strong> empty wooden pallets.Potential source <strong>of</strong> risk:• pallets at ground level• size <strong>of</strong> pallets• weight <strong>of</strong> pallets can beup to 35 kg.Reduction <strong>of</strong> risk may involvethe use <strong>of</strong> mechanical aidsor the use <strong>of</strong> one or more <strong>of</strong>the following;• use hand pallet jack tomove pallets• use lighter weights<strong>of</strong>twood or plasticpallets, and/or• team handling <strong>of</strong> palletswithin the BWZ.Racking system, workplacedesign and layout, andwork practices for theremoval or transfer <strong>of</strong> palletsensure that;• use <strong>of</strong> a racking systemwith roller conveyorshelving capable <strong>of</strong>discharging empty palletsfor removal by forkliftAutomatic pallet removaltechnology.• removal, transfer, andstacking <strong>of</strong> pallets isdone mechanically or byforklift or other form <strong>of</strong>mechanical aid• employees do notmanually handle pallets.28 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
11.Plant (machineryand equipment)While there are significant issues surrounding traffic management and the safe<strong>operation</strong> <strong>of</strong> machinery and equipment in the <strong>cold</strong> <strong>storage</strong> industry, there are similarconcerns relating to the maintenance and <strong>operation</strong> <strong>of</strong> the numerous refrigerationsystems used in these workplaces.The <strong>storage</strong> and use <strong>of</strong> large quantities <strong>of</strong> anhydrous ammonia in refrigerationsystems can pose a risk to employees, adjoining premises and surroundingcommunity. The majority <strong>of</strong> risk and reported incidents where anhydrous ammoniahas been involved are attributed to poor design and installation <strong>of</strong> refrigeration plantand/or a lack <strong>of</strong> inspection and maintenance and deficiencies with the plant<strong>operation</strong>al procedures.Refrigeration plant and equipmentWhile the duties on the designers, owners and operators <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> toensure the selection, use and maintenance <strong>of</strong> workplace plant and equipment doesnot present a risk to employees, employers must (S. 23) also ensure that otherpeople who are not employees are also not exposed to risks arising from the conduct<strong>of</strong> the undertaking <strong>of</strong> the employer.This means employers must ensure that any activity or the <strong>operation</strong> <strong>of</strong> plantand equipment at the workplace does not present a risk to employees, contractorsor others.A number <strong>of</strong> incidents and inspections <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> have raised concernsabout the safe <strong>operation</strong> and maintenance <strong>of</strong> refrigeration systems in <strong>cold</strong> <strong>storage</strong><strong>facilities</strong>. These concerns relate to the risks to employees, adjoining premises and thesurrounding community from the large quantities <strong>of</strong> anhydrous ammonia stored andused at the workplace. This concern, combined with lack <strong>of</strong> security at these sitescan present a significant risk to the broader community.Cold <strong>storage</strong> <strong>facilities</strong> must be proactive in the development and implementation <strong>of</strong>preventative maintenance programs and systems to effectively monitor and controlthe use <strong>of</strong> the plant and dangerous refrigerants.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 29
11.Plant (machinery and equipment)Risk control regarding refrigeration plant should take into account the following aspects:1. Design and construction <strong>of</strong> plant – the design <strong>of</strong> the refrigeration plant shouldmeet published technical standards (e.g. Australian Standards) and the plant mustbe tested (e.g. hydrostatic pressure testing and x-ray examination) in line with therequirements <strong>of</strong> the relevant standard.2. Work<strong>Safe</strong> licensing – pressure vessels associated with the refrigeration plant mayhave to be Design Registered with Work<strong>Safe</strong> if they are specified in Schedule 2 <strong>of</strong>the Occupational Health and <strong>Safe</strong>ty Regulations 2007. A design registrationnumber must be provided to the customer by the supplier <strong>of</strong> the vessel. Theindividual vessels may then have to be an Item <strong>of</strong> Plant Registered with Work<strong>Safe</strong>,again if included in Schedule 2.3. Inspection and maintenance – refrigeration vessels covered by Schedule 2 arerequired to be periodically inspected (frequency <strong>of</strong> inspection as per manufacturerrecommendation or Australian Standard AS 3788:2006 Table 4.1). Ongoingpreventative maintenance must be conducted in conjunction with periodicinspection <strong>of</strong> the plant.4. Ammonia release – safe discharge <strong>of</strong> anhydrous ammonia to ensure excessrefrigerant is discharged to a safe location (e.g. not inside confined rooms butaway from employee work areas and neighbouring properties).More information:AS/NZS 1677.2:1998 Refrigerating systems – <strong>Safe</strong>ty requirements for fi xed applicationsAS 3788:2006 – Pressure Equipment – In service InspectionAS 3873:2001 – Pressure Equipment, Operation and MaintenanceAS 4024.1:2006 – <strong>Safe</strong>ty <strong>of</strong> MachineryAS 2022:2003 – Anhydrous Ammonia (Storage & Handling)Checklist – Anhydrous Ammonia Refrigeration Systems (Appendix 6)Dangerous Goods Act 1985Dangerous Goods (Storage & Handling) Regulations 200030 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
11.Plant (machinery and equipment)Forklifts and material handling equipmentAlthough forklifts and other forms <strong>of</strong> materials-handling equipment are extensivelyused in the <strong>cold</strong> <strong>storage</strong> industry, these items <strong>of</strong> plant type are overrepresented inthe number <strong>of</strong> workplace incidents and fatalities. As a result, Work<strong>Safe</strong> <strong>Victoria</strong> hasdeveloped and implemented a number <strong>of</strong> compliance based initiatives that include;• a requirement for seatbelts to be retrospectively fitted to forklifts,• the compulsory use <strong>of</strong> seat belts by forklift operators, and• where there is interaction between pedestrian and forklift traffic, the developmentand implementation <strong>of</strong> an effective traffic management plan.Features now readily available and that should be considered when leasing orpurchasing forklift trucks include:• ergonomic designs, including rotating cabins for travelling in reverse and fullyadjustable tilting cabins for overhead work,• electronic interlock or pedestrian-forklift zone sensing systems that effectivelycontrol forklift movement, operate boom gates on roadways or gate locking deviceson pedestrian walkways,• insulated and heated cabins to control employee exposure to wind chill, exposure,<strong>cold</strong> stress, and the level <strong>of</strong> fatigue from working in <strong>cold</strong> environments,• air quality monitoring devices to continually monitor oxygen levels and air qualityin freezers, <strong>cold</strong> stores or other confined areas <strong>of</strong> a <strong>cold</strong> <strong>storage</strong> facility,• closed circuit television and mast mounted cameras for positioning and theretrieval <strong>of</strong> stock from the upper sections <strong>of</strong> racking, and• computerised and electronic interlock devices to ensure seatbelts are worn byoperators during forklift <strong>operation</strong>.More information:AS 4024.1 – <strong>Safe</strong>ty <strong>of</strong> MachineryWork<strong>Safe</strong> publications: Forklift <strong>Safe</strong>ty Reducing the Risk<strong>Safe</strong>ty by Design – Eliminating manual handling injuriesin road transportWork<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 31
11.Plant (machinery and equipment)Forklifts and mobile plantHigh risk examples Medium risk solutions Low risk solutionsInappropriate and poorlymaintained forklifts:• not fitted with seat belts• not appropriately inspectedand tested• not maintained tomanufacturer specifications• not suitable for the workbeing undertaken• have attachments that are notmatched to specific forklift• not compliant to therelevant standard• has a compliance plate that isnot authentic• operator has no forklift licence(to perform high risk work) and isnot under training and instruction• operator has no experienceoperating equipment.Cold <strong>storage</strong> facility has beenappropriately designed and uses wellmaintained battery or electric poweredforklift trucks with:• computerised automatic guidedvehicle (AGV) systems that do notrequire operators• interlocking devices to ensure thecompulsory use <strong>of</strong> seat belts• fitted electronic interlock orpedestrian or forklift zone sensingsystems that:- effectively control forklifttruck movement- operate roadway boom gatesand gate locking devices onpedestrian walkways• heated cabins designed for workin <strong>cold</strong> environments• continually monitor air quality andoxygen levels• mast mounted cameras and closedcircuit television monitors in forkliftcabins for positioning and theretrieval <strong>of</strong> stock from the uppersections <strong>of</strong> racking• automatic height levelling systemspre-programmed to racking heights• operated by competent, experiencedand licensed persons.32 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
11.Plant (machinery and equipment)Refrigeration plant and systemsHigh risk examples Medium risk solutions Low risk solutionsCold <strong>storage</strong> facility refrigeration plantand system is in poor condition and:• has not been installed or maintainedto the relevant standards• has piping, valves, gauges and othercomponents that are not clearlymarked and identified• pressure plant and equipment that is:- not registered with Work<strong>Safe</strong>- not appropriately inspectedor tested by a suitablyqualified person;• there is no maintenance programto ensure the safe <strong>operation</strong> <strong>of</strong> therefrigeration plant or systems• is not operated by an appropriatelytrained and competent person• access to refrigeration plant is notsecurely restricted or appropriatelycontrolled• relief valves and discharge pipingoutlets are not appropriately locatedand are directed toward work areasor adjoining properties• there is no monitoring <strong>of</strong> therefrigeration system to detect leaks• there is no emergency managementplan to effectively control risks toemployees, adjoining premises or thelocal community.Cold <strong>storage</strong> facility has a refrigerationsystem that has:• been designed, installed, and ismaintained to the relevant standards• plant pipe work, gauges, valves andother components that are clearlylabelled and readily identified• pressure vessels registeredwith Work<strong>Safe</strong> (applies to thosespecified in Schedule 2 <strong>of</strong> OHSRegulations 2007)• inspections and testing bya suitably qualified person• operated by a competent andexperienced person• fitted with appropriate safetyfeatures to detect and isolateany leak• an alarm or other warning device toalert the appropriate persons whenany leak is detected• appropriately located relief valvesand discharge piping outletsdirected away from work areasand adjoining properties• adequate security and restrictedaccess to areas where plant is located.Refer: Dangerous Goods Act 1985Dangerous Goods (Storage & Handling)Regulations 2000;AS 3788:2006 – Pressure Equipment– In service Inspection;AS 3873:2001 – Pressure Equipment –Operation and Maintenance.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 33
11.Plant (machinery and equipment)General plantHigh risk examples Medium risk solutions Low risk solutionsPlant and machinery that:• are not provided and or maintainedin a condition that is safe to use• does not have adequate guardingor suitable risk controls to preventaccess to the dangerous parts <strong>of</strong>the machinery during its <strong>operation</strong>• is not regularly inspected or testedto ensure that it remains safe to use• has not been designed, and/orinstalled in line with manufacturerspecifications or the appropriatestandard• does not have instructions orprocedures necessary for theinstallation, use, and maintenance<strong>of</strong> the plant.Plant and machinery at the workplaceis selected and purchased in consultationwith employees to ensure:• all plant and equipment has beendesigned and manufactured to theappropriate standards• it is fitted with appropriate guardingto prevent access to the dangerareas <strong>of</strong> the plant or equipment• it is inspected, tested and maintainedto manufacturer specifications andthe relevant standards• employees have received adequateinformation, instruction and trainingbefore the commissioning or use <strong>of</strong>the plant or equipment.Refer: AS 4024.1 <strong>Safe</strong>ty <strong>of</strong> Machinery34 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
12.EmergencymanagementVarious factors must be considered by employers and operators <strong>of</strong> <strong>cold</strong> <strong>storage</strong><strong>facilities</strong> when determining the types <strong>of</strong> hazards and the level <strong>of</strong> risk to employees,adjoining premises and the broader community during a fire or other emergency atthe workplace.The use <strong>of</strong> styrene as an insulation material, and the volume <strong>of</strong> anhydrous ammoniaused and stored in refrigeration systems at <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong>, needs to beconsidered when determining the potential type and consequence <strong>of</strong> any emergencyat the workplace.To mitigate the risks to those that may be affected by any emergency – particularlywhere substantial quantities <strong>of</strong> dangerous goods may be involved – there are prescriptiverequirements designed to identify, assess and control risks.A fire audit report is required to have been prepared and an emergency managementplan developed.Any emergency management plan must be developed in consultation withemployees, and should involve both adjoining premises or workplaces and theemergency services that may be required to respond to any emergency situationat the workplace.More information: Dangerous Goods Act 1985Dangerous Goods (Storage & Handling) Regulations 2000Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 35
12.Emergency managementEmergency management planHigh risk examples Medium risk solutions Low risk solutionsEmergency management is inadequate:• emergency managementplan and emergency evacuationprocedures has not beendeveloped or tested• no adequate consultation with:- employees and contractors- emergency services- adjoining premisesand/or workplaces• types and potential impact<strong>of</strong> emergencies have not beenidentified or assessed• is no effective system forcommunicating with:- employees, contractors or visitorson site- adjoining premises or workplacesthat may have an impact on orbe affected by the emergency- appropriate emergency servicesIn the event <strong>of</strong> an emergencyat the workplace:• emergency services vehicles do notreceive adequate direction• access to the site or the location<strong>of</strong> the emergency is impededor restricted• emergency assembly areas are:- not clearly marked- poorly positioned- not communicated to all thoseon site.The workplace has a formalemergency management plan andevacuation procedure:• developed and implemented inconsultation with:- employees and contractors- relevant emergency services- adjoining premisesand/or workplaces• potential emergencies identified,assessed and planned for:• consideration given to the impacton and from hazards and risks atadjoining premises• consideration given to ensureemergency services areable to respond in time• ensures is unrestricted access foremergency services• appropriate training and instructionprovided to employees and visitors(e.g. contractors and truck drivers)• there is an effective communicationsystem (e.g. public address system)to all areas <strong>of</strong> the site• emergency communication system,evacuation drills and the emergencymanagement plan is tested andreviewed regularly.Refer: Dangerous Goods Act 1985Dangerous Goods (Storage & Handling)Regulations 200036 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
12.Emergency managementEmergency management planHigh risk examples Medium risk solutions Low risk solutionsFacility has not provided an adequatelevel <strong>of</strong> site security and:• unrestricted access to site• no control over unauthorised accessto hazardous or high traffic areas,(eg. dock area)• unrestricted access to plant roomsand chemical and dangerous goods<strong>storage</strong> area.Facility developed, and implemented anappropriate level <strong>of</strong> site security:• strictly applied, monitored andregularly reviewed• effectively controls and monitors allaccess to and from the site (e.g.electronic swipe card for employees,and log in and out at security gate)• controls all access to hazardous areas(e.g. refrigeration plant, dock areas)• ensures supervisory control over allvisitors and contractors.Refer: Dangerous Goods Act 1985Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 37
13.AcknowledgementsWork<strong>Safe</strong> would like to acknowledge and thank the following organisations and theirindividual representatives for their valuable contribution to the development <strong>of</strong> this guide:Shaw Idea P/L and the Cold Storage Project Steering CommitteeNational Union <strong>of</strong> WorkersAustralian Metal Workers UnionAustralian Institute <strong>of</strong> Refrigeration Air-conditioning and HeatingAustralasian Meat Industry Employees UnionToyota Material Handling (Vic) P/LTransport Workers UnionDexion Australia P/LDr Andrew Baigent (Consulting Engineer)Polar Fresh Chain Services P/LColes Group LimitedVersa<strong>cold</strong> Logistic LimitedRegal Cream Products P/LMcKey Distributions P/LSWIRE Cold Storage Pty. Ltd.SPC ARDMONA Operations LimitedP. Pullar & Co (Cobram) P/LAnspac Cold Storage P/LMcCain Foods (Aust) P/L38 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
14.AppendicesAppendix 1Design <strong>of</strong> a safe <strong>cold</strong> <strong>storage</strong> workplaceThe following chart sets out the basic steps to establish an effective design process.Getting started 1. Establish specifications that consider:1.1 Client needs (e.g. efficient product movement/throughput, sufficient <strong>storage</strong> space).1.2 Outcomes <strong>of</strong> preliminary consultation withusers and suppliers.1.3 Requirements <strong>of</strong> these guidelines, particularlythe listed design factors to be considered.Develop design 2. Develop preliminary design options forconsideration by client and users.3. Consult with client, users and suppliers.4. Determine design based on the outcomes<strong>of</strong> consultation.5. Test, refine and validate design to ensurecompliance with these guidelines.Employer to consult the relevant HSRsand workforce during the processBuild design 6. Finalise and execute design.More information: A guide to Section 28 <strong>of</strong> the Occupational Health and <strong>Safe</strong>ty Act 2004 – Designing <strong>Safe</strong>r Buildings and StructuresWork<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 39
14.AppendicesAppendix 2Wind Chill ProgramWind chill for temperatures from +5 to -20°CTair (°C)V10 5 0 -5 -10 -15 -20(km/h)5 4 -2 -7 -13 -19 -2410 3 -3 -9 -15 -21 -2715 2 -4 -11 -17 -23 -2920 1 -5 -12 -18 -24 -3025 1 -6 -12 -19 -25 -3230 0 -6 -13 -20 -26 -3335 0 -7 -14 -20 -27 -3340 -1 -7 -14 -21 -27 -3445 -1 -8 -15 -21 -28 -3550 -1 -8 -15 -22 -29 -3555 -2 -8 -15 -22 -29 -3660 -2 -9 -16 -23 -30 -3665 -2 -9 -16 -23 -30 -3770 -2 -9 -16 -23 -30 -3775 -3 -10 -17 -24 -31 -3880 -3 -10 -17 -24 -31 -38Frostbite GuideLow risk <strong>of</strong>frostbite formost peopleIncreasing risk <strong>of</strong>frostbite for mostpeople within 30minutes <strong>of</strong>exposureHigh risk for mostpeople in 5 to10 minutes <strong>of</strong>exposureHigh risk formost people in2 to 5 minutes<strong>of</strong> exposureHigh risk for mostpeople in 2minutes <strong>of</strong>exposure or lessWind chill for temperatures from -25 to -50°CTair (°C)V10 -25 -30 -35 -40 -45 -50(km/h)5 -30 -36 -41 -47 -53 -5810 -33 -39 -45 -51 -57 -6315 -35 -41 -48 -54 -60 -6620 -37 -43 -49 -56 -62 -6825 -38 -44 -51 -57 -64 -7030 -39 -46 -52 -59 -65 -7235 -40 -47 -53 -60 -66 -7340 -41 -48 -54 -61 -68 -7445 -42 -48 -55 -62 -69 -7550 -42 -49 -56 -63 -69 -7655 -43 -50 -57 -63 -70 -7760 -43 -50 -57 -64 -71 -7865 -44 -51 -58 -65 -72 -7970 -44 -51 -58 -65 -72 -8075 -45 -52 -59 -66 -73 -8080 -45 -52 -60 -67 -74 -8Tair = Actual Air Temperature in °CV10 = Wind Speed at 10 metres in km/h(as reported in weather observations)Notes:1. For a given combination <strong>of</strong> temperature and windspeed, the wind chill index corresponds roughly tothe temperature that one would feel in a very lightwind. For example, a temperature <strong>of</strong> -25°C and awind speed <strong>of</strong> 20 km/h give a wind chill index <strong>of</strong>-37. This means that, with a wind <strong>of</strong> 20 km/h anda temperature <strong>of</strong> -25°C, one would feel as if it were-37°C in a very light wind.2. Wind chill does not affect objects and does notlower the actual temperature. It only describes howa human being would feel in the wind at theambient temperature.3. The wind chill index does not take into accountthe effect <strong>of</strong> sunshine. Bright sunshine may reducethe effect <strong>of</strong> wind chill (make it feel warmer) by6 to 10 units.40 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
14.AppendicesAppendix 3Operation <strong>of</strong> LPG forklift trucks in poorly ventilated placesIntroductionForklifts are used in many industries to handle and move materials. Petrol, diesel andliquid petroleum gas (LPG) powered forklifts emit a range <strong>of</strong> hazardous airbornecontaminants from their exhausts, including carbon monoxide (CO). LPG forkliftsgenerally have a ‘cleaner’ exhaust than petrol or diesel powered engines, yet can stillproduce dangerous levels <strong>of</strong> CO and other airborne contaminants if they are used ina poorly ventilated place, such as a cool store or freezer room.The use <strong>of</strong> poorly maintained LPG forklifts in poorly ventilated spaces posessignificant risks.The health effects <strong>of</strong> carbon monoxide (CO)CO is a colourless and odourless gas. It interferes with oxygen delivery to the tissuesin the body. The heart and the central nervous system are the main areas <strong>of</strong> the bodyaffected by CO poisoning.The early symptoms <strong>of</strong> CO poisoning include headaches and nausea. Prolongedexposure may result in dizziness, collapse, unconsciousness, coma and death. Theseverity <strong>of</strong> the effects depends on the level and length <strong>of</strong> exposure. As CO has nosmell, people exposed to high levels may have little or no warning before theycollapse. A person who has experienced a high level <strong>of</strong> exposure may sufferpermanent damage to the heart or central nervous system.Exposure standard for carbon monoxideThe Australian national exposure standard for CO is 30 parts per million (ppm)measured at the worker’s breathing zone averaged over an eight hour day (timeweighted average or (TWA)), five day working week. Those using or interpretingexposure standards should refer to the Hazardous Substances Information System(HSIS) published by Australian <strong>Safe</strong>ty and Compensation Council on its internet sitethat also considers short term exposure and the toxicological effects <strong>of</strong> CO.Risk control measuresTo eliminate the risk <strong>of</strong> CO poisoning, electric forklifts should be used in poorlyventilated areas. It is much safer to use electric forklifts for entry and work in poorlyventilated places such as cool stores and freezer rooms. Electric forklifts trucksshould be used in preference to petrol, diesel or LPG-powered forklift trucks in poorlyventilated places.Some workplaces use LPG forklifts in poorly ventilated places when battery poweredor electric forklifts are not available or if their use is not practicable. If LPG forklifts areused in poorly ventilated places then a high level <strong>of</strong> control needs to be in place tomake sure that employees are not exposed to a dangerous level <strong>of</strong> CO.A documented safe work practice outlining the use <strong>of</strong> LPG forklifts in poorlyventilated spaces needs to be developed and put into practice, in consultation withhealth and safety representatives. A documented safe work procedure should addressthe following points:Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 41
14.AppendicesTuning, carburetion systems and fuel• Test the exhaust emission levels in the tail pipe <strong>of</strong> the forklift• Ensure the forklift is tuned to yield an exhaust gas containing:- not more than 0.2% (2000 ppm) CO at idling, and- not more than 0.1 % (1000 ppm) CO at speed (no load).These tuning levels are readily achievable without affecting the performance <strong>of</strong> theLPG forklift and have been widely used in Australia for several decades.• Retest and retune the forklift for CO emission:- each week until carburettor stability is known and at less frequent intervalsafter that,- if the brand or composition <strong>of</strong> the fuel changes, and- if work is carried out on the carburetion or ignition systems.• Document the results <strong>of</strong> CO emission testing and tuning. This will help toassess the ability <strong>of</strong> the forklift to hold its tune. It will also help to identify theneed for future maintenance through detecting early changes in the state <strong>of</strong> tune(maintenance on forklifts should follow the manufacturer’s recommendation).• Seek a guarantee <strong>of</strong> consistent composition <strong>of</strong> automotive grade LPG fromsuppliers. If the propane/butane ratio <strong>of</strong> LPG changes between batches this willaffect the concentration <strong>of</strong> CO emitted in the exhaust <strong>of</strong> forklifts.• Fit a stable, tamper-resistant carburetion system to the LPG forklift.• Avoid using dual fuel carburetion systems such as petrol and LPG. If dual fuelcarburetion systems are used, ensure that forklifts are powered by LPG whileentering and working in poorly ventilated places. Changing the fuel sourcebetween petrol and LPG will affect the tune <strong>of</strong> the engine, so ensure that enginesare properly tuned and tested when operated in LPG mode.• Consider fitting forklifts with a catalytic purifier to further lower CO emission.However, catalytic purifiers have little or no impact on lowering the CO emissionlevels <strong>of</strong> a forklift which is not tuned properly.Acceptable air quality• Maintain acceptable air quality when operating LPG forklifts in poorly ventilatedplaces. Use a CO gas detector to check that CO levels in the breathing zone <strong>of</strong>employees do not exceed the exposure standard. The CO monitor should be set toalarm at 30 ppm. CO exposure may vary from person to person depending on thesystem <strong>of</strong> work. An assessment needs to be carried out to determine the number<strong>of</strong> CO monitors required. In some cases it may be necessary for each individualentering the cool store to be allocated or wear a CO monitor.• Use mechanical ventilation if LPG forklifts have to be used for entry for extendedperiods, such as for continuous work.Administrative controls• Ensure electric or LPG forklifts to be used in poorly ventilated places are identifiedfrom those not to be used in these areas (e.g. signage, colour).• Ensure the engine <strong>of</strong> the forklift is turned <strong>of</strong>f when not in use to avoid unnecessarybuild-up <strong>of</strong> exhaust fumes.• Put emergency procedures in place which include rescue and first aid42 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
14.Appendices• Train employees working on tasks associated with the use <strong>of</strong> LPG forklifts inpoorly ventilated places, including:- health effects and warning signs <strong>of</strong> exposure to CO- control measures in place (including documented safe work procedures)- use <strong>of</strong> atmospheric testing equipment- what to do if the alarm on the CO monitor activates- correct tuning techniques for LPG forklifts (for mechanics).Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 43
14.AppendicesAppendix 4Long-term fruit <strong>storage</strong> in controlled atmosphere roomsIntroductionControlled atmosphere (CA) <strong>storage</strong> is used to slow deterioration and maintain thequality <strong>of</strong> stone fruit for many months. The term CA <strong>storage</strong> means cooling to a lowtemperature and control <strong>of</strong> oxygen and carbon dioxide levels in a gas tight cool store.The oxygen concentration in the air we breathe is normally about 21%. It isconsidered safe between 19.5% and 23.5%. Typically, controlled atmosphere roomshave very low levels <strong>of</strong> oxygen, with oxygen levels around 1 to 2% during <strong>operation</strong>.These reduced levels <strong>of</strong> oxygen will result in unconsciousness without warning afterinhaling a single breath, and death within minutes. If the person survives thenpermanent brain and heart damage are likely. Rescuers spontaneously respondingto the sight <strong>of</strong> the unconscious person could also become victims.If entry and exit to an operating CA room is restricted (e.g. through a hole in ceiling)then the Confined Spaces Part <strong>of</strong> Occupational Health and <strong>Safe</strong>ty Regulations2007 applies.People may be at risk <strong>of</strong> exposure to an oxygen deficient atmosphere when operatingin CA rooms or working nearby. Some examples <strong>of</strong> dangerous situations are:• if a CA system is activated while a person is locked inside the room,• entering an activated CA room (Never enter an operating CA room),• when a person opens an activated CA room,• entering into a CA room which has recently been opened and is being ventilated,and• if a person is located in a poorly ventilated area next to a CA room which has beenopened and is being ventilated.Risk control measuresEntry should not be made to a CA room while it is operating.Ensure that opening and closing <strong>of</strong> CA rooms is done by a person authorisedby the employer who oversees the safe work procedures.A documented safe work practice outlining the <strong>operation</strong> <strong>of</strong> the CA room needs to bedeveloped and put into practice in consultation with health and safety representatives.A documented safe work procedure should address the following points:Closing a CA roomEnsure all people have left the CA room, close and lock the doors.• Signpost the doors with clear and prominent signs that warn people not to enterthe room (e.g. DANGER. Keep Out. Atmosphere deadly if inhaled).• Activate the CA system.Opening a CA room• Ensure the opening <strong>of</strong> the CA room is closely supervised and observed bya second person who understands and follows the safe work procedures.• Place a barricade made from cones, ropes or other portable barriers in a semicircleat least three metres from the doorway to stop unauthorised access.44 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
14.Appendices• Ensure people not involved with opening the doors are kept well away fromthe immediate vicinity. These persons need be instructed and trained.• Place a prominent DANGER sign alongside the portable barriers(as described above).• Record the time <strong>of</strong> opening on the sign.• Provide adequate ventilation in areas adjacent to the door before opening theCA room. If these areas are poorly ventilated or enclosed they must be barricadedto stop unauthorised access.• Unlock the door and open to its fullest extent. Ensure people openingthe room reduce their risk <strong>of</strong> exposure to an oxygen deficient atmosphere byquickly moving away from the room to a pre-identified ventilated area while thedoors are open.• Ventilate the room with fresh air until the oxygen level is at least 19.5%.Ventilation is usually carried out by opening the doors and turning on therefrigeration fans. The time taken to ventilate will vary depending on the room size,internal structure and the ventilation rate. It may assist to determine how long ittakes to ventilate the CA room. This information will help to work out the timerequired to undertake future ventilation.• Measure oxygen levels inside the room using an oxygen gas detector that iscorrectly calibrated and maintained as recommended by the manufacturer.• Measurements should be taken by a competent person who is able to follow themanufacturer’s instructions and correctly interpret the results. The tester shouldNOT enter the room while taking the measurements and the measurementsshould be taken by placing a probe into the room before the CA is activated. Theprobe should be connected to a recorder outside the room.• Declare the room safe for entry only when the oxygen level is 19.5-21%.• Record the atmospheric test results and the time the store was declared safe.• Remove portable barriers and signs and start normal work activities again.Administrative controls• Prohibit entry to a CA room while it is in <strong>operation</strong>.• Ensure the control system for the CA room is isolated so it cannot be operatedwhile people are in the cool store.• Put emergency procedures in place which include rescue and first aid.• Training for employees should include:- health effects and warning signs <strong>of</strong> oxygen deficiency,- control measures in place, including documented safe work procedures,- the use <strong>of</strong> atmospheric testing equipment, and- emergency procedures.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 45
14.AppendicesAppendix 5Protective Clothing for Cold Storage – A Users’ GuideProtective Clothing for Cold Storage – A Users’ GuideContentsIntroduction 46Types <strong>of</strong> <strong>cold</strong> stress 47Risk management <strong>of</strong> <strong>cold</strong> stress 47Protective clothing and equipment as a risk control 47Factors to consider when selecting personal protective equipment 53Environmental factors 53Work-related factors 54Worker-related factors 54Specific factors to consider 54Clothing 54Boots 56Gloves 57Headgear 57IntroductionA <strong>cold</strong> environment is defined as an environment under which greater than normalheat losses are anticipated and compensatory thermoregulatory actions are required.That is, attention must be paid to the heat escaping our bodies and actions taken todo something about it. Cold stress is defined as the stress resulting from the net heatloss on the body or the net heat loss on a portion <strong>of</strong> the body such as feet, hands,limbs or head.Exposure to <strong>cold</strong> environments may produce shivering, vasoconstriction, increasedoxygen consumption, accelerated respiration and pulse rate, elevated blood pressureand a significant increase in cardiac output. Severe or prolonged exposure to <strong>cold</strong>may result in cerebral blood flow, effects on the central nervous system and mayaffect renal and liver function. In the event <strong>of</strong> abnormal reduction in core bodytemperature, hypothermia – a life threatening condition – may result. The range<strong>of</strong> acceptable deep core temperature variation for workers exposed to <strong>cold</strong> is verysmall with an allowable change <strong>of</strong> only + or – .1 to .4° <strong>of</strong> the normal body temperature<strong>of</strong> 37.6°.Recognising <strong>cold</strong> stress and hypothermia as a workplace health risk is important inestablishing the required controls to prevent serious injury or illness.46 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
14.AppendicesTypes <strong>of</strong> Cold Stress• whole-body cooling• local cooling, including extremity cooling, convective skin cooling (wind chill),conductive skin cooling (contact cooling) and cooling <strong>of</strong> respiratory tract.Most likely, several if not all <strong>of</strong> these may be present at the same time.Classification <strong>of</strong> <strong>cold</strong> workTemperature Type <strong>of</strong> work Type <strong>of</strong> <strong>cold</strong> stress10° to 20° Sedentary, light work, finemanual work0° to10° Sedentary and stationary,light work-10° to 0° Light physical work, handlingtools and materials-20° to -10° Moderate activity, handlingmetals and fluids (petrol, etc.),windy conditionsWhole-body cooling, extremitycoolingWhole-body cooling, extremitycoolingWhole-body cooling, extremitycooling, contact coolingWhole-body cooling, extremitycooling, contact cooling,convective coolingBelow -20° All types <strong>of</strong> work All types <strong>of</strong> <strong>cold</strong> stressRisk management <strong>of</strong> <strong>cold</strong> stressThe Occupational Health and <strong>Safe</strong>ty Act 2004 requires risks to health and safetybe controlled so far as is reasonably practicable. This means that employers needto identify, assess and consider risk controls which eliminate the hazard at its sourceas the primary form <strong>of</strong> risk control. If the hazard is unable to be eliminated, engineeredout or the hazardous task, object, substance, etc. substituted with something saferthen, only then, can personal protective equipment be used as a form <strong>of</strong> risk control.Protective clothing and equipment as a risk controlProtective clothing and equipment is a common risk control for employees exposed to<strong>cold</strong> environments. However, it is not a good idea to rely solely on protective clothingand equipment to control risk as it may not properly protect all employees from risksand at the same time can create new risks and work problems.As far as reasonably practicable, controls other than the use <strong>of</strong> protective clothing andequipment should be used to manage risks arising from exposure to <strong>cold</strong>.Personal protective clothing and equipment should be seen as a temporary measureor a last resort to be used only when other controls may not adequately controlexposure, or are not reasonably practicable.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 47
14.AppendicesRisks <strong>of</strong> using protective clothing and equipmentPersonal protective clothing and equipment is not a good risk control because it:• does not eliminate or reduce the risks and dangers• may not be cost effective - <strong>of</strong>ten the long term monetary and employee time costs<strong>of</strong> using protective clothing and equipment are not taken into account, such as thecosts <strong>of</strong>:- selecting- storing- cleaning- fitting- medical examinations required before use- purchasing- replacing- maintaining- training employees in use and maintenance- monitoring <strong>of</strong> use and extra supervision.• only provides limited protection• will not protect employees if it is not properly selected, fitted, used, maintainedand stored• is <strong>of</strong>ten less effective if more than one type <strong>of</strong> personal protective clothing andequipment is used at the same time• is not always used when it should because it:- interferes with doing the job- causes discomfort and/or pain- affects vision (e.g. safety goggles, full face respirators)- interferes with hearing and talking (e.g. hearing protection, respirators)- is not used by some employees for health, physical and psychological reasons)- is difficult to use correctly if not properly supervised- interferes with employee concentration.Protective clothing and equipment can increase manual handling risks by:• making work harder that in turn may increase sweating and the risk <strong>of</strong> <strong>cold</strong> stress• restricting postures and movements making the job harder to do and increasingthe chance that protective clothing and equipment won’t be properly used (e.g.gloves can prevent getting a good grip on tools, components and materials - thisputs more physical stress on the hands, arms and shoulders).48 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
14.AppendicesSteps to follow before using protective clothing and equipment asa risk controlStep 1A risk assessment should be completed prior to the selection and use <strong>of</strong> any protectiveclothing and equipment and should be undertaken in consultation with those employeesand HSRs for whom the protective clothing and equipment will be provided.Step 2If the risk assessment shows that risk controls are needed, the following must beconsidered when consulting employees and the relevant HSRs who may be exposedto <strong>cold</strong> work environments:• eliminating exposure to <strong>cold</strong>• isolating employees from the <strong>cold</strong>• engineering controls that reduce employee exposure to <strong>cold</strong>• modifying or altering the systems <strong>of</strong> work to eliminate or reduce employeeexposure to <strong>cold</strong>.If these risk controls are not reasonably practicable in the short term then appropriateprotective clothing and equipment may be suitable as a temporary risk control.Elimination <strong>of</strong> Hazard/RiskYesNoReplace Hazard/Risk with something less hazardousNoYesDoes this control the Hazard?YesNoIsolate the Hazard/Risk from peopleNoYesDoes this control the Hazard?YesProtective clothing andequipment not requiredNoEngineering controls to control the Hazard/RiskNoYesDoes this control the Hazard?YesNoDo administrative changes control the Hazard/Risk?NoYesDoes this control the Hazard?YesNoGo to step 3Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 49
14.AppendicesStep 3This checklist will help determine if protective clothing and equipment is a suitablerisk control. It identifies factors that may need to be addressed when using protectiveclothing and equipment as a risk control. Answers in a red box indicate protectiveclothing and equipment may not be a suitable primary risk control.YesNoHave employees exposed to <strong>cold</strong> and HSRs been consulted aboutthe use <strong>of</strong> protective clothing and equipment?Is there protective clothing and equipment that will effectively protectemployees from the <strong>cold</strong>?Is this protective clothing and equipment readily available?Will the protective clothing and equipment interfere with visionand communication?Will any exposed employees be unable to use the protective clothingand equipment due to physical, psychological or medical factors?Will the protective clothing and equipment interfere with thejob or task?Will using protective clothing and equipment create other risks, e.g.manual handling risks or heat stress?Step 4Take action to address any problems indicated by ticks in any <strong>of</strong> the red boxesas identified in Step 3.50 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
14.AppendicesStep 5Implement an effective personal protective clothing and equipment programWhen protective clothing and equipment is used as a temporary risk control aprotective clothing and equipment program should be in place and reviewed regularly.This checklist contains the essential requirements <strong>of</strong> an effective program and can beused to evaluate an existing program. Answers in a green box indicate therequirement has been satisfied.Requirement Yes No N/ADid the employer establish the program?Did the employer consult employees and HSRs whenestablishing the program?Are employees and HSRs active participants in theprogram, involved in its planning, implementation, monitoringand evaluation?Is someone designated to be responsible for the program?Does that person have the full support <strong>of</strong> employees andthe employer?Is there an effective procedure for dealing with situationswhere clothing and equipment are not being used as required?Does the procedure for selecting protective clothing andequipment include consultation?Are the following considerations met when selectingprotective clothing and equipment?• Is it comfortable and a good fit?• Does it interfere with the job?• Does it provide employees with choice?• Does it cater for differences between employees?• Does it provide adequate levels <strong>of</strong> protection?• Can it be used together with other clothing and equipment?Is there medical screening <strong>of</strong> each employee assigned towear respirators?Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 51
14.AppendicesRequirement Yes No N/AAre employees and supervisors (including labour hire andcontractors) appropriately trained in:• the program• why the program is the only reasonably practicable riskcontrol solution at present• future risk controls which may replace the use <strong>of</strong> protectiveclothing and equipment• proper use and fitting• how to test the correct fit <strong>of</strong> the equipment(e.g. respirators)• cleaning, <strong>storage</strong>, maintenance and replacement• the limitations <strong>of</strong> the equipment and clothing• the risks, dangers, and need for protection• when, where and how the clothing and equipment isto be used• how any problems/issues with the equipment and its useare to be reported and fixed.Is clothing and equipment supplied to each employee for theiruse when reasonably practicable?Do employees get a copy <strong>of</strong> the operator’s manual for theclothing and equipment provided?Is there proper fitting and testing <strong>of</strong> clothing and equipment?Is there regular cleaning/disinfecting <strong>of</strong> clothing and equipment?Is proper no contamination <strong>storage</strong> for the clothing andequipment available?Is there periodic inspection and maintenance <strong>of</strong> the equipmentand/or replacement as required according to the instructions<strong>of</strong> the manufacturer or supplier?Is enough employee time allocated for training, fitting,cleaning and rest breaks (if necessary) when usingsome equipment?Are there procedures for non-routine situations such asspills and leaks?Is there regular assessment <strong>of</strong> the program to ensureprocedures are being followed and employees are beingproperly protected?52 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
14.AppendicesStep 6Protective clothing and equipment is a temporary measure, a last resort, only to beused when other risk controls do not control exposure or are not reasonablypracticable and Steps 1-5 have been completed.If protective clothing and equipment is being used for extended periods in aworkplace, then alternative risk controls may not have been properly considered.It is the employer’s responsibility to provide protective clothing and equipment foremployees, including those from labour hire employeesStep 7A continuous improvement approach is essential. This includes annual reviews <strong>of</strong>:• changes in knowledge about the effects <strong>of</strong> <strong>cold</strong> on health• existing, and any new, risks due to changes in work processes• changes in technology and state <strong>of</strong> knowledge about risk control measuresincluding elimination, substitution, engineering and changing systems <strong>of</strong> work orwork practices• changes in technology and state <strong>of</strong> knowledge about protective clothingand equipment• the workplace’s protective clothing and equipment program.The basis for these reviews can be steps 1, 2 and 3.Factors to consider when selecting personalprotective equipment:Environmental factors to considerIn designing out risks posed by <strong>cold</strong> stress it is important to look at the workenvironment and identify the sources <strong>of</strong> <strong>cold</strong>, for example plant used, work processesand practices. In addition effects <strong>of</strong> <strong>cold</strong> on the body are influenced by environmentalfactors including:• Air temperature – how hot or <strong>cold</strong> the surrounding air is• Humidity – the moisture content in the air• Air movement – including air/wind speed and air circulation.Work related factors to considerIn addition to environmental factors which can increase the effect <strong>of</strong> <strong>cold</strong> on workersthe following factors should be considered when identifying and assessing hazardsassociated with working in <strong>cold</strong> environments:• Source <strong>of</strong> <strong>cold</strong>:- What working conditions expose employees to <strong>cold</strong> (e.g. high wind chill, wetworkplaces, poor temperature control, frequently changing temperatures)?• Nature <strong>of</strong> the work undertaken:- How does the work being done interact with or generate <strong>cold</strong> conditions (e.g.highly physical work increases sweating decreasing body temperature, vehicle<strong>operation</strong> increases wind chill, working in confined spaces)?• Nature <strong>of</strong> materials being used in tasks:- The type <strong>of</strong> material being handled during a task will affect the risk <strong>of</strong>skin damage.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 53
14.Appendices• Duration <strong>of</strong> exposure to <strong>cold</strong>:- Risks to health and safety will be increased by the length <strong>of</strong> time workers areexposed to <strong>cold</strong> (e.g. prolonged physical activity in <strong>cold</strong> or wet conditions).Worker related factors to considerWhile factors relevant to an individual worker need not exclude them from workingin a <strong>cold</strong> environment they should be identified to ensure special consideration <strong>of</strong> aworker’s need when assessing risks associated with working in <strong>cold</strong> environments.This is also important to ensure the workplace is designed appropriately toaccommodate any special considerations.• Does the person have any physical or medical health conditions that make themmore likely to be affected by <strong>cold</strong>?• Are they affected by medication, drugs or alcohol which may make them moresusceptible to <strong>cold</strong>?• Are they experienced in and acclimatised to working in <strong>cold</strong> environments?Specific factors to consider:ClothingThe following features must be considered when choosingclothing for work in chillers and freezers.1. Fit• Clothing needs to fit properly.• Clothing that is stretched tight does not insulate effectively.• Pay particular attention to knees and elbows – clothing should be looserover joints.• Inner layers need to be flexible and fit closely.• Outer layers must be large enough to be worn over the inner layerswithout stretching.• Clothing must be easily adjustable for size and with openings at the neck andwrists, under sleeves and down the front to adjust ventilation to cool down orwarm up.• If separate jackets and trousers are worn, make sure there is enough overlapbetween the jacket and the trousers to prevent <strong>cold</strong> air getting in at the waist.2. Visibility• Reflective and fluorescent colours are needed for visibility, particularly in hightraffic areas.• Having reflective and fluorescent panels and strips as part <strong>of</strong> freezer gear is muchbetter than separate vests, which can catch on equipment and cause slips, tripsand falls.3. Insulation• Clothing slows heat loss from the body, but it has to provide dry air next to the skin.• Insulation value <strong>of</strong> clothing is proportional to its thickness.• Layers provide greater insulation because they trap extra dry air between the layers.• Wearing layers allows you to cool down by removing layers as you get warmby doing physical activities.54 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
14.Appendices• Appropriate level <strong>of</strong> insulation will depend on the temperature in the freezer andwork being done – the <strong>cold</strong>er the environment, the greater the insulation neededfrom clothing.• Intensity <strong>of</strong> the work activity will also affect the level <strong>of</strong> insulation requiredparticularly if a variety <strong>of</strong> different jobs are being done. Layers are the bestarrangement. This means that workers can remove or add layers, dependingon the work they are doing.• Clothing must be easy to put on and take <strong>of</strong>f and fabrics chosen to reduce frictionbetween layers.• Fabrics used between outer and inner layers should create air spaces to provideinsulation. They should be lightweight and absorbent so they can trap water vapouraway from the skin so that it can pass through the outer layer. They need to beresilient and able to ‘spring back’ when compressed (e.g. by bending over). Wooland other fibrous materials are suitable.• The clothing should be designed so that bending over does not cause too muchcompression <strong>of</strong> the layers and therefore loss <strong>of</strong> insulation.4. Water resistance• Clothing must remain dry for the insulation properties to continue to work, requiringchanges <strong>of</strong> clothing during the work shift, particularly if moderate or heavy workis being done.• Drying rooms must be conveniently located and be big enough so that workerscan remove outer layers and dry them out.• Inner fabrics should be able to wick or draw sweat away from the skin to beabsorbed in the middle layer and breathed out through the outer layer. A number<strong>of</strong> new fabrics are now being used for close fitting undergarments suitable forwearing under freezer jackets.5. Fasteners• Buttons do not provide enough insulation, creating openings for <strong>cold</strong> air to get in.• Zippers must be able to function in freezing temperatures and be used by <strong>cold</strong> andgloved hands.6. Durability• Clothing must be durable and strong enough to resist tears if caught on protrusions.• Torn fabric does not insulate effectively.7. Spares and cleaning• Increasing fatigue and discomfort over a shift happens because frequent entry andexit from freezers and chillers makes clothing wet and <strong>cold</strong>.• Water vapour is created by sweating while working in freezers and this turns intowater in clothing when workers move into the warm humid air outside freezers.• Increasing water in clothing reduces insulation and wet protective clothing canactually make people even <strong>cold</strong>er as the clothing dries. Employees therefore needchanges <strong>of</strong> clothing whenever they get wet, either from ice melting on the clothingor from sweat as a result <strong>of</strong> physical activity.• Dirty clothing also has reduced insulation properties because it is less effective attrapping air.• Regular laundering is critical and clothing must be easily washed. This means eachemployee needs at least three sets <strong>of</strong> protective gear: one set to wear, one set tohave as spare in case clothing gets wet and one set being laundered.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 55
14.AppendicesBootsBoots are very important – feet are one <strong>of</strong> the most likelyparts <strong>of</strong> the body to be adversely affected by <strong>cold</strong>.The following features <strong>of</strong> boots should be consideredwhen choosing the right sort <strong>of</strong> protection.1. InsulationBoots can be lined with insulating materials such as fur or fabric or canvas or feltover-boots (to midcalf) can be used to increase insulation. Soles as well as uppersneed to be well insulated. Cold will go through a thin sole to damage feet.2. SizeLarge enough so that you can wear several pairs <strong>of</strong> socks and use an insole toimprove insulation.3. Water resistanceAbility to repel water if there is any chance that ice or water will fall on the boot. Wetboots do not provide thermal insulation.4. VentilationWell-ventilated to keep the surface next to the feet dry. If possible, boots shouldhave a vapour barrier that wicks moisture away from the feet to help keep the innersurface dry.If this is not possible, socks and insoles need to be replaced frequently and wheneverthey get wet. Boots must dry completely between shifts.5. FlexibilitySoles must be flexible, particularly if you need to operate foot controls.6. Anti-slipTread must be able to prevent slipping on wet or icy floors.7. Impact resistanceSteel capped boots should only be used as a last resort as steel conducts the <strong>cold</strong>very well and makes feet even <strong>cold</strong>er.Caps made from carbon fibre or plastics that do not go brittle in severe <strong>cold</strong> mayprovide sufficient impact resistance without conducting <strong>cold</strong> to the toes.8. Interaction with clothingBoots must fit with trouser legs effectively so that <strong>cold</strong> air cannot get in through anygaps. Trouser legs can fit under or over boots but must seal properly.56 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
14.AppendicesGlovesLike feet, hands are most likely to be affected by the <strong>cold</strong>. Thetypes <strong>of</strong> materials being touched can increase the impact <strong>of</strong><strong>cold</strong> on skin. The extremities, in particular fingers and toes, aresusceptible to cooling. Unless sufficient heat input by warmblood can be maintained, tissue temperature progressivelyfalls. Extremity blood flow is determined by energetic (requiredfor muscles activity) as well as thermoregulatory needs. When whole-body thermalbalance is challenged, peripheral vasoconstriction helps to reduce core heat lossesat the expense <strong>of</strong> peripheral tissues. With high activity more heat is available andextremity blood flow can more easily be maintained.The protection <strong>of</strong>fered by hand wear and footwear in terms <strong>of</strong> reducing heat lossesis limited. When heat input to the extremity is low (e.g. with resting or low activity),the insulation required to keep hands and feet warm is very large (van Dilla, Day andSiple, 1949). The protection <strong>of</strong>fered by gloves and mittens only provides retardation<strong>of</strong> cooling rate and, correspondingly, longer times to reach a critical temperature.With higher activity levels, improved protection allows warm hands and feet at lowerambient temperatures.The following features <strong>of</strong> gloves should be considered when choosing the right sort<strong>of</strong> protection.1. InsulationMittens are better than gloves for keeping hands warm. Gloves should provide thewarmth <strong>of</strong> a mitten with the manual dexterity allowed by a glove, and as such allowthe wearer to perform multiple tasks without having to remove the gloves.Good fit is essential with gloves so that work tasks can be completed. If mittens arebeing used, gloves may need to be worn underneath so that mittens can be removedfor certain jobs (e.g. using RF equipment or operating controls on forklifts).2. Interaction with clothingSleeves <strong>of</strong> jackets should fit, sealing over or under the cuff <strong>of</strong> the gloves or mittens toprevent <strong>cold</strong> air getting in. They should also be attached to jackets so that they do notget lost when removed.HeadgearA lot <strong>of</strong> heat from your body is lost through your head making wearing headgear veryimportant in freezers. The following factors should be taken into account whenchoosing headgear.1. ProtectionHeadgear must protect ears and neck and be windpro<strong>of</strong>. The combination <strong>of</strong>a knitted beanie with a hood from a freezer jacket can provide the necessary level<strong>of</strong> protection. It also lets you remove layers to cool down when doing harder work.Balaclavas that cover your face and pull down onto the neck completely may benecessary in extreme <strong>cold</strong> or when doing sedentary work.2. Interaction with other gearHeadgear must not interfere with other types <strong>of</strong> protective gear, e.g. hearingprotection, safety glasses.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 57
Appendix 6 – Checklist: Anhydrous ammonia refrigerating systemsItem Regulation, Actor StandardQuestions YES orNOa.Material <strong>Safe</strong>tyData Sheet(MSDS)Dangerous Goods(Storage & Handling)Regulations 2000,Reg. 438 (MSDS)Is a current MSDS for anhydrous ammonia readilyaccessible to employees and contractors on site?(Has it been reviewed within the past five years?)b.Notificationto Work<strong>Safe</strong><strong>Victoria</strong> <strong>of</strong>dangerousgoods on siteDangerous Goods(Storage & Handling)Regulations 2000,Reg.506-Notification tothe AuthorityDetermine quantity <strong>of</strong> anhydrous ammonia held inthe refrigeration system.If 500 litres or more <strong>of</strong> anhydrous ammonia, hasWork<strong>Safe</strong> been notified <strong>of</strong> the presence <strong>of</strong> thesedangerous goods?c.Planning foremergenciesDangerous Goods(Storage & Handling)Regulations 2000,Reg. 437 - Planningfor emergenciesIf 500 litres or more <strong>of</strong> anhydrous ammonia heldon site, there needs to be a written emergencymanagement plan developed in consultation withrelevant fire services.If no written plan and the quantity is less than500 litres, there should be an emergency plan asrequired under the general provisions <strong>of</strong> DangerousGoods (Storage & Handling) Regulations 2000,Regulation 444.If quantity <strong>of</strong> ammonia is 2000L or more, has theoccupier installed a fire protection system that is fully<strong>operation</strong> and been developed in consultation withthe relevant fire services?GuidanceGuidance: Occupier is required to have a current (no older than fi ve years)Material <strong>Safe</strong>ty Data Sheet (MSDS) readily accessible to any persons engagedby the occupier and any emergency services attending the site.Guidance: Quantity <strong>of</strong> ammonia in the refrigeration system is the water holdingcapacity <strong>of</strong> receiver. The volume/quantity should be stamped on the receiver.Guidance: Occupier should have a copy <strong>of</strong> the lodgement <strong>of</strong> theNotifi cation <strong>of</strong> Dangerous goods <strong>storage</strong> and handling sent to Work<strong>Safe</strong>and/or a return receipt.Guidance: Occupier should have a written plan for dealing with emergenciesthat is currently in use and readily available.If the quantity <strong>of</strong> anhydrous ammonia is 500 litres or more, the plan needs to bedeveloped in consultation with the fi re services.Guidance: Documented plan or procedure for dealing with an anhydrousammonia leak:• wind directional devices, windsocks? (To assist in evacuating the site)• manifest and Emergency Plan available to emergency services in event<strong>of</strong> an incident• evacuation procedures – designated evacuation zones in place• shutdown procedure for the refrigeration system in the event <strong>of</strong> an incident• plan or system that readily identifi es the function and location <strong>of</strong> valves so thatany leak or incident involving the refrigeration system can be isolated.Main isolation valves clearly labelled.Guidance: Verify a fi re protection report has been issued by the Fire Servicesand the occupier has complied with the requirements outlined within the report.(Compliance with the report can be demonstrated when the occupier is able toproduce a formal letter <strong>of</strong> compliance issued by the Fire Service).58 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
Checklist: Anhydrous ammonia refrigerating systems (con’t)Item Regulation, Actor StandardQuestions YES orNOd.Incidents tobe reportedDangerous GoodsAct 1985, Section 32Would an anhydrous ammonia leak be reported topolice or relevant fire authority as required underDangerous Goods Act 1985?Occupational Healthand <strong>Safe</strong>ty Act 2004,Section 38Would the employer notify Work<strong>Safe</strong> in the event <strong>of</strong>an ammonia leak that results in injury to any personthat requires medical treatment as defined in Section38 <strong>of</strong> the Occupational Health and <strong>Safe</strong>ty Act 2004GuidanceGuidance: Occupier should have formal procedures outlined within theemergency plan to meet this reporting requirement.Guidance: Occupier should have formal procedures outlined within theemergency plan to meet this reporting requirement.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 59
Checklist: Anhydrous ammonia refrigerating systems (con’t)Item Regulation, Actor StandardQuestions YES orNOe.Maintenancesystems inplace forammoniarefrigerationsystemDangerous Goods(Storage & Handling)Regulations 2000,Reg. 407 - Generalduty to control risk.Has the occupier implemented adequate risk-controlmeasures associated with the safe <strong>storage</strong> andhandling <strong>of</strong> anhydrous ammonia within therefrigeration system?Dangerous Goods(Storage & Handling)Regulations 2000,Reg. 418 - Structureand plant – conditionand repairIs there a formal and effective preventativemaintenance system or program in place for theanhydrous ammonia refrigeration plant andequipment?Is the anhydrous ammonia refrigeration plant and thepreventative maintenance system operated in-houseor by external contractors or combination <strong>of</strong> both?Are those responsible for the maintenance and<strong>operation</strong> <strong>of</strong> the anhydrous ammonia refrigerationplant and equipment suitably trained?GuidanceGuidance: Occupier is required to demonstrate that there are adequate riskcontrols in place. This can be achieved by conducting a formal self-assessmentagainst AS 1677 Refrigeration systems.Refrigeration systems. Part 1: Refrigerant classifi cationsRefrigeration systems. Part 2: <strong>Safe</strong>ty requirements for fi xed applicationsNote: If other codes or standards are used they need to demonstratecompliance to an equivalent level <strong>of</strong> AS 1677Guidance: Occupier is required to demonstrate that there is an effectivemaintenance system in place which is formally recorded within a register, andclearly lists and identifi es safety items that are critical to the safe <strong>operation</strong> <strong>of</strong> therefrigeration system such as:• safety relief valves• ventilation systems• detectors (if provided)• critical operating valves• sensors fi tted to level indicators• high and low level alarms• pressure vessel inspected. Refer: AS3788:2006 Pressure Equipment – InService Inspection• intrinsically safe electrical equipment and wiring (where detectors are notprovided refer: AS1677 Part 2 clause 4.7.6)Occupier should be able to demonstrate that the appropriate maintenanceregime is being provided on all items identifi ed in the register.Guidance: Occupier has formal records which confi rm employees and/orcontractors responsible for the <strong>operation</strong> and maintenance <strong>of</strong> the anhydrousammonia refrigeration plant and equipment at the workplace have receivedappropriate training.60 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
Checklist: Anhydrous ammonia refrigerating systems (con’t)Item Regulation, Actor StandardQuestions YES orNOGuidanceIs there a copy <strong>of</strong> the operating and maintenancemanual for the refrigeration plant and equipment onsite and readily accessible? (Refer: AS 1677Refrigeration systems Part 2 <strong>Safe</strong>ty requirements forfixed applications Clause 6.2.1)Guidance: The Occupier has a copy <strong>of</strong> the operating and maintenance manualas required under the provisions <strong>of</strong> Dangerous Goods (Storage & Handling)Regulations 2000, Reg. 402.Formal safe work procedures:• identify and control the risks associated with the safe <strong>operation</strong> andmaintenance <strong>of</strong> the anhydrous ammonia plant and equipment• require that a <strong>Safe</strong> Work Method (SWM) is undertaken prior to anymaintenance work• have one or more permit systems in place for maintenance work (e.g. hotwork, confi ned space entry).Are premises and vessels adequately placarded? Guidance: There must be outer warning placarding “HAZCHEM” provided atevery road vehicle entry where the quantity <strong>of</strong> anhydrous ammonia on site is 500litres or more. Refer: Dangerous Goods (Storage & Handling) Regulations 2000,Reg. 429.Where capacity <strong>of</strong> the bulk container (receiver) is greater than 500 litres,appropriate placarding must be provided on the vessel.Refer: Dangerous Goods (Storage & Handling) Regulations 2000, Reg. 430.Is there adequate first aid <strong>facilities</strong> and emergencyequipment such as safety shower/eye wash stationclose to the refrigeration plant room?Guidance: Hazards and risks associated within the <strong>storage</strong> and any handling<strong>of</strong> corrosive materials such as anhydrous ammonia must be identifi ed andappropriately controlled. The level <strong>of</strong> exposure to corrosive materials such asanhydrous ammonia during charging <strong>of</strong> and maintenance to the refrigerationplant and equipment will determine what risk control measures, such asemergency and medical equipment, may be required (e.g. eye wash, safetyshower, fi rst aid <strong>facilities</strong>).Refer: Dangerous Goods (Storage and Handling) Regulations 2000, (Reg. 405)f.Site andinstallation <strong>of</strong>refrigerationsystemDangerous Goods(Storage & Handling)Regulations 2000,Reg. 425 -Ventilation andatmosphericemissionsIf the refrigeration plant and equipment is locatedwithin a room/building, appropriate natural ormechanical ventilation will be required?Guidance: Refrigeration plant and equipment located indoors needs to beeither naturally or mechanically ventilated. (For specifi c ventilation rates referto Table 4.1 AS 1677 Refrigreration systems Part 2: <strong>Safe</strong>ty requirements forfi xed applications).Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 61
Checklist: Anhydrous ammonia refrigerating systems (con’t)Item Regulation, Actor StandardQuestions YES orNOGuidanceg.HazardouszonesIf the system is located in the open, are there anypotential ignitions sources within in 1.5 metres <strong>of</strong> therefrigeration plant and equipment?Guidance: If there are ignition sources within 1.5 metres <strong>of</strong> the refrigerationplant then a hazardous zone risk assessment needs to be conducted as perAS 2430. Classifi cation <strong>of</strong> hazardous areas.Is the system is located in a room or space? Guidance: Then all electrics in that room or spaced should be suitable tooperate in a zoned hazardous area. AS 2430. Classifi cation <strong>of</strong> hazardous areas.h.Site andinstallation <strong>of</strong>refrigerationsystemDangerous Goods(Storage & Handling)Regulations 2000AS 1677RefrigerationsystemsAS 1345Identification <strong>of</strong>contents <strong>of</strong> pipesIs refrigerant piping protected againstvehicle impact?Is pipe-work appropriately marked accordingto AS1345?Guidance: Is refrigerant plant, equipment and piping appropriately protectedfrom impact damage by vehicles or mobile plant etc. Refer: Dangerous Goods(Storage & Handling) Regulations, Reg 421.Guidance: Liquid and vapour pipe lines must be capable <strong>of</strong> being readilyidentifi ed and marked or colour coded in the appropriate colours asper AS 1345 .Colours as defi ned in AS 1345:Background: Yellow-ochre (Straw, Sand, sandstone, Raffi a, Biscuit)Writing: BlackDirectional arrow showing fl ow directionAMMONIAIf the refrigeration system is located within anenclosed room or space where people may enterand work is there an audible and visible evacuationalarm system?Guidance: Where persons are required to work near evaporators (containinganhydrous ammonia) the occupier should have one or more gas detectorsinstalled in the work area to provide early warning in the event <strong>of</strong> a refrigerantleak and before persons are exposed to dangerous concentrations <strong>of</strong> therefrigerant anhydrous ammonia.Note: There are potential health risks for asphyxiation to occur where thereis a leakage <strong>of</strong> gas. Refer: AS Refrigerating systems 1677 Part2: <strong>Safe</strong>tyrequirements for fi xed applications, Clause 4.8.1.62 Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> Work<strong>Safe</strong> <strong>Victoria</strong>
Checklist: Anhydrous ammonia refrigerating systems (con’t)Item Regulation, Actor StandardQuestions YES orNO• Is personal protective equipment (PPE) provided?• Is the PPE maintained? (Breathing apparatus(BA) set if required)• Is PPE readily available?• Is there PPE appropriately stored?• Are there appropriate records to verifymaintenance <strong>of</strong> PPE?Are relevant people trained and currently competentin the use <strong>of</strong> the PPE? (BA set)i.Induction,information,training andsupervisionDangerous Goods(Storage & Handling)Regulations 2000,Reg. 402.Are people involved with daily <strong>operation</strong> <strong>of</strong> theanhydrous ammonia refrigeration system suitablytrained and aware <strong>of</strong> the hazards and risksassociated with the refrigeration plant andequipment and the refrigerant (anhydrousammonia) used?GuidanceGuidance: For anhydrous ammonia amounts;• ≤ 225kg 1 respirator required• > 225kg’s 2 respirator required• 900kg’s 1 self-contained BA with effective life <strong>of</strong> 25mins + PPEto AS2022 required including maintenance <strong>of</strong> equipmentGuidance: Suitable training must be provided to those who may be required touse a BA set and emergency drills should be conducted to review and ensureemergency procedures are adequate.Guidance: Occupier must ensure employees and contractors involved in the<strong>operation</strong> and maintenance <strong>of</strong> the refrigeration plant and equipment havereceived appropriate information, instruction and training. Records verifyinginduction or any other hazard or competency based training has been providedshould be maintained with records <strong>of</strong> safety and tool box meetings.Work<strong>Safe</strong> <strong>Victoria</strong> Handbook <strong>Safe</strong> <strong>operation</strong> <strong>of</strong> <strong>cold</strong> <strong>storage</strong> <strong>facilities</strong> 63
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Work<strong>Safe</strong> <strong>Victoria</strong>Advisory Service222 Exhibition StreetMelbourne 3000Phone 03 9641 1444Toll-free 1800 136 089Email info@worksafe.vic.gov.auHead Office222 Exhibition StreetMelbourne 3000Phone 03 9641 1555Toll-free 1800 136 089Website worksafe.vic.gov.auLocal OfficesBallarat 03 5338 4444Bendigo 03 5443 8866Dandenong 03 8792 9000Geelong 03 5226 1200Melbourne(628 Bourke Street) 03 9941 0558Mildura 03 5021 4001Mulgrave 03 9565 9444Preston 03 9485 4555Shepparton 03 5831 8260Traralgon 03 5174 8900Wangaratta 03 5721 8588Warrnambool 03 5564 3200VWA1130/01/04.08